Firestorm Labs Squall FPV Drone

History

The Squall is a light electric first-person-view unmanned aerial vehicle developed by the American company Firestorm Labs. Its largely printable airframe is intended to support distributed production, repair, and configuration close to the point of use.

In 2026, Firestorm Labs and United States service members manufactured 12 Squall drones aboard the Wasp-class amphibious assault ship USS Essex. The aircraft were built while the ship sailed to Hawaii for Exercise Rim of the Pacific 2026, demonstrating that FPV drones could be produced aboard a deployed warship.

The completed aircraft subsequently flew as adversary drones during a counter-unmanned-aircraft exercise in Hawaii. The demonstration connected shipboard manufacturing, assembly, and flight operations in a single deployment.

Development concept

Firestorm Labs designed the Squall around an airframe whose principal structural components can be manufactured with additive-production equipment. The concept separates printable parts from reusable or stored subsystems such as motors, batteries, flight controllers, cameras, and radio equipment. This arrangement allows forces to transport compact component stocks and manufacture airframes according to demand instead of carrying only complete aircraft.

The Squall is associated with Firestorm Labs' xCell production system. The xCell is a transportable microfactory installed in a standardized container. It combines additive-manufacturing equipment, digital preparation tools, and assembly workstations. The container can be placed aboard a ship or moved to a forward or expeditionary position without requiring a permanent production facility.

USS Essex demonstration

During a two-week deployment in 2026, the xCell aboard USS Essex produced more than 1,000 parts. Some of these components were used to assemble 12 Squall FPV drones, while others supported mechanical testing and repairs aboard the ship. Production continued while the vessel encountered seas reported at up to 3.7 m (12 ft).

Service members participated in model preparation, printing, component inspection, electronics installation, and final assembly. The activity was part of the Naval Postgraduate School Consortium for Advanced Manufacturing Research and Education distributed advanced-manufacturing network. FLEETWERX facilitated the operation during the ship's voyage to Exercise Rim of the Pacific 2026.

The at-sea production demonstration was reported by Army Recognition and Navy Times. Both accounts identified the aircraft produced aboard USS Essex as Firestorm Labs' Squall FPV drone.

Design

Airframe

The Squall uses a largely printable airframe. Reported printable elements include fuselage sections, arms, and payload mounts. A damaged printable component can therefore be replaced without discarding the complete aircraft or its reusable electronic and propulsion equipment.

This construction method supports decentralized manufacturing. Digital models and printing material provide the structural parts, while stored kits supply the components that cannot be printed. The design also permits replacement parts to be produced near the operating unit when compatible manufacturing equipment and materials are available.

Propulsion and control equipment

The Squall is electrically powered. Its stored non-printed components include batteries and motors. Flight controllers manage the aircraft, while cameras and radio links provide the first-person-view control function. The available evidence does not identify the specific motor arrangement, battery capacity, control frequency, or flight endurance of the aircraft produced aboard USS Essex.

Production system

The xCell converts digital design files, printing material, and stored subsystems into complete unmanned aircraft and replacement components. Its workflow includes preparation of the digital model, additive manufacturing, inspection of printed parts, integration of electronics, assembly, and operational testing.

Containerization allows the production equipment to move as a single transportable installation. During the USS Essex demonstration, the xCell operated inside the existing logistics and workshop environment of an amphibious assault ship. The trial showed that ship motion and sea conditions did not prevent continued production during the reported voyage.

The system does not eliminate conventional logistics. Batteries, motors, sensors, flight-control equipment, radio components, and printing material still require storage and replenishment. Its principal logistical effect is to reduce reliance on stocks of complete airframes and allow structural components to be manufactured or replaced at the point of need.

Operational history

After USS Essex arrived in Hawaii, the 12 Squall drones assembled during the voyage were used as adversary aircraft in a counter-drone exercise associated with RIMPAC 2026. The aircraft provided training targets manufactured during transit rather than delivered to the ship as complete drones from a shore facility.

The demonstration established a confirmed training role for the ship-produced Squall aircraft. Although reports discussed possible reconnaissance and light-strike applications for FPV drones of this type, the supplied evidence confirms only their use as adversary aircraft during the counter-unmanned-aircraft exercise. It does not establish operational deployment of an armed Squall variant.

Operators

• United States: United States service members assembled Squall drones aboard USS Essex and operated the completed aircraft as adversary targets during a counter-drone exercise at RIMPAC 2026.

Specifications (Squall FPV drone)

General characteristics

• Type: Light first-person-view unmanned aerial vehicle
• Manufacturer: Firestorm Labs
• Power source: Electric battery
• Airframe: Largely additively manufactured structure with replaceable printable components
• Control equipment: Flight controller, camera, and radio link

Production demonstration

• Aircraft manufactured aboard USS Essex: 12
• Parts produced by the xCell during the deployment: More than 1,000
• Reported sea conditions during production: Waves up to 3.7 m (12 ft)
• Demonstrated role: Adversary aircraft for counter-unmanned-aircraft training