A team from the 28th Infantry Division of the Pennsylvania National Guard won first place in the innovation category in the U.S. Army’s inaugural Best Drone Warfighter Competition, underscoring the increasing role of additive manufacturing in tactical drone operations.
The event, held February 17–19 at the Huntsville Test Range, brought together active-duty, National Guard, and Army Reserve personnel across three contests: Best Operator, Best Tactical Squad, and Best Innovation.
The 28th Infantry Division’s team (1st Lt. Ryan Giallonardo, Chief Warrant Officer 3 Robert Reed, Chief Warrant Officer 2 Nathan Shea, and Sgt. 1st Class Brent Wehr) was recognized for Project R.E.D. (Recovery Exploitation Drone), a drone-based recovery platform integrating AI-enabled detection with a 3D printed robotic subsystem.
Carbon Fiber 3D Printing for Battlefield Drone Retrieval
Project R.E.D. focuses on locating and retrieving downed unmanned aerial systems (UAS) for intelligence gathering or refurbishment. The system combines AI-driven object recognition with a lightweight carbon fiber robotic arm, 3D printed for strength and precision, equipped with a claw to grasp and transport drones from contested areas.
“This is a great achievement for the team and the UAS facility as well as the Pennsylvania National Guard as a whole,” said Reed, the 28th Infantry Division team captain. “Competing against the entire Army, putting in the work and coming out on top really speaks volumes to what the team has been doing and the hard work they’ve been putting in, and it highlights the Pennsylvania National Guard and what we’re able to accomplish.”
From Technical Pitch to Field Validation
The competition began with a Shark Tank-style pitch and concluded with a live operational demonstration. Judges assessed both conceptual design and field performance.
“The judges were very impressed with everything we went through,” Reed said. “We got a lot of positive feedback and a lot of opportunity to continue working further with the Army Research Laboratory. They were highly impressed with what we were able to put together.”
The team received a commemorative plaque, an Army Research Lab prototype drone, and a one-year research and development partnership, enabling collaboration to refine and improve the platform.
“We’re excited to continue to have incredible support from state and division level leadership,” Reed said. “They’ve been very helpful and very supportive of everything we’re doing, and it’s allowing us to highlight what we can do at our facility. And, I’m super proud of my entire team and everything they’re doing.”
Broader Participation
Beyond the innovation category, Capt. Christopher Rongione competed in the operator division, while Wehr and Sgt. Tyler Beck took on the tactical squad’s hunter-killer challenge, which combined physical endurance tasks with drone-based reconnaissance and engagement operations.
Operational Impact of Project R.E.D.
Project R.E.D. demonstrates how 3D printing can transform U.S. battlefield drone operations by enabling rapid recovery and exploitation of downed UAS. Within the U.S. Army context, drone losses have traditionally slowed missions, exposed personnel to risk, and created dependency on centralized logistics and repair facilities. By combining a 3D printed carbon fiber robotic arm with AI-enabled detection, Project R.E.D. allows units to quickly reclaim and redeploy drones, turning disabled assets into intelligence sources or operational tools.
This capability shifts tactical decision-making: units can act on drone losses without pausing missions. Similar efforts highlight how additive manufacturing is enabling immediate, mission-driven production: the U.S. Air Force awarded Firestorm Labs a $100 million contract to produce modular 3D printed unmanned aerial systems.
Firestorm’s xCell system has already manufactured and repaired drones and components during exercises like Project Convergence‑Capstone 5, producing mission-critical UAS platforms without reliance on central factory infrastructure.
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Featured image shows A team of Pennsylvania National Guard Soldiers from the 28th Infantry Division won the innovation competition at the U.S. Army’s inaugural Best Drone Warfighter Competition. Photo via National Guard.
