FAIRFAX, VIRGINIA, US — U.S. defense contractor MAG Aerospace has partnered with Australian technology firm Rocket Fast Drones to develop and produce a family of tube-launched, 3D-printable unmanned aerial systems (UAS). The collaboration aims to provide cost-effective aircraft for military missions, including counter-drone operations, intelligence, surveillance and reconnaissance (ISR), electronic warfare and strike missions.
The partnership combines MAG Aerospace’s experience in systems integration, unmanned aircraft operations and defense programmes with Rocket Fast Drones’ scalable unmanned aircraft technology.
Tube-Launched Unmanned Aircraft
The electric vertical takeoff and landing (VTOL) aircraft are designed for rapid launch from tubes or cases without requiring runways, catapults or complex field assembly. The systems can also be launched from ground, air and ship-based platforms.
The current flight-tested lineup includes four models: EP90, EP150, EP250 and EP450, with diameters ranging from 90 mm to 450 mm (approximately 4 to 18 inches).
The aircraft can reach speeds of up to 155 mph (249 km/h) and operate over a range of up to 40 nautical miles (74 km). Their open architecture supports modular payloads weighing between 0.3 and 2.2 pounds, with a maximum payload capacity of approximately 1 kg.
The four models have different performance specifications:
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EP90: Gross weight of 1.7 pounds, 0.3-pound payload and 75 mph cruise speed.
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EP150: Gross weight of 1.7 pounds, 0.3-pound payload and 106 mph cruise speed.
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EP250: Gross weight of 10 pounds, 2.2-pound payload and 98 mph cruise speed.
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EP450: Gross weight of 10.9 pounds, 1.7-pound payload and 58 mph cruise speed.
Autonomous Operations and Field Manufacturing
The systems are designed to conduct autonomous point-to-point flights, including beyond visual line of sight and in GPS-degraded or jammed environments. Their software also supports swarm operations for coordinated air- or ground-launched effects.
The aircraft can transition from vertical takeoff to horizontal flight and perform autonomous waypoint missions. They are designed to land vertically for recovery and reuse after completing a mission.
A key feature is the use of 3D printing for nearly the entire airframe, allowing the aircraft to be assembled in the field. The design uses a glueless, tool-less assembly approach, while the autopilot board and flight control software remain outside the 3D-printing process.
The companies aim to reduce production costs and support the use of the aircraft as attritable or expendable assets when required. Optional field-manufacturing licences include training, manuals and printing files.
Modular Payloads and Production Capacity
The open architecture allows the aircraft to carry different mission payloads, including kinetic warheads, electronic warfare jammers or decoys, cameras, battlefield blood transport systems and CBRNE microsensors.
The companies said small-volume production is available, with manufacturing capacity expected to reach 100 aircraft per month within nine months.
The aircraft have demonstrated vertical takeoff, transition to horizontal flight, manual control and autonomous waypoint missions. Their technology readiness levels are reported at 6–7.
Partnership Targets Cost-Effective Drone Operations
MAG Aerospace recently displayed the four flight-tested models at the Association of the U.S. Army (AUSA) conference.
The partnership aims to address cost imbalances observed in recent Middle East conflicts, where expensive counter-unmanned aircraft systems have been used against lower-cost drones.
MAG Chief Engineer Matt Jessup said these conflicts highlighted the financial challenges of countering inexpensive unmanned systems.
Rocket Fast Drones CEO Dr. Joni Sytsma said the partnership would help transition the company’s technology into operational military environments at scale.
The collaboration combines MAG’s operational experience, integration capabilities and U.S. defense relationships with Rocket Fast Drones’ scalable aircraft platforms to support the development and deployment of adaptable unmanned systems.
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