It’s the dead of night when the buzz of the engines of a series of Shahed-136 one-way attack drones breaks the silence. Carrying their lethal payloads the drones slip into the darkness with a distant supply base as their target. Tracking, identifying, and then destroying this swarm of drones is no easy task.

The unmanned aircraft system (UAS) threat environment is changing rapidly with an increasing variety of killer drones that demand differing methods of tracking and identification to engage and defeat them. Operational users are learning from rapidly-evolving- conflicts, and modern air defense methods increasingly rely on scalable, layered, and persistent sensing teams that can detect and track small, fast, low-altitude, and even swarming, aerial threats in all kinds of complex situations, on land or at sea.

Ray Bischoff served active-duty with the U.S. Army for nearly 25 years, and he’s now the senior director of business development at Leonardo DRS, specialising in evaluating tactical formations and defensive requirements at all operational levels throughout the Department of War and allied nations. He is particularly focused on emerging threats from drones..

Bischoff spoke at length with TWZ’s Jamie Hunter about the use of tactical radar systems as part of a layered counter-drone system that is sufficiently versatile to tackle the toughest drone problems now, and what may come in the near future.

JH: Can you set the scene with regards to how you see the counter-UAS mission right now from a sensing perspective.

RB: The counter-UAS environment is changing and advancing very quickly. At the top level, we need to employ a variety of sensor systems – in this particular case we’re talking about tactical radars – but there are many other types of sensors, and at the highest end of the threat level it’s about connecting these together into a networked architecture.

Layering different systems in depth is vital, both from a communications architecture perspective and physically layering them in different places to protect different routes or avenues of approach, or sensitive facilities.

Look at the Strait of Hormuz, for instance, which is a vast area, with a layered and networked system to maximize the depth of coverage. The primary reason for this is that the biggest enemy in many situations like these is time. That networked architecture and having sensors in depth really gains you time, which gives you opportunities to make a better decision, time to reposition, to better evaluate. You need time to evaluate what different things in space are doing, where they’re going or where they’re coming from.

JH: When you say layered, are you talking about different systems that can look in different ways over different distances and systems in different positions that help you with that time element? What does layered actually mean?

RB: You can layer different types of sensors. Think of baseball. If all your players are home-run hitters, you probably aren’t going to do very well. You need to have different skills across your team to succeed, and it’s the same thing here. Layering of radar sensing bands, different types of technology such as electro-optic and infra-red that “see” in long, short and midwave, acoustic sensors, electronic warfare sensors to look for signals and other types of energy. It’s also about physically layering them in space, or depth.

We often see large exquisite sensors that have a lot of range and cover a large area. But this makes them susceptible to being targeted and destroyed. Layering sensors gives you redundancy, retaining the ability to defend. So, this is layering both in physical location, and in different types of technology.

This way, if one of your sensors is taken down by any means – for example by electronic countermeasures – your other systems can theoretically continue to operate. Just think how you can see, smell, touch, taste – it’s the same concept with layering different types of technologies, which is exactly what we at Leonardo DRS do and we integrate them so we can interact and share information to maximize the benefits of this layered approach. A team ultimately makes the sensors more effective across networks and architectures.

JH: Presumably you get good indicators on developments from the current operations in Ukraine. You already mentioned the Strait of Hormuz as well. What are the big lessons that you’re getting here about different types and sizes of drones?

RB: Without going into the details of combat operations, the bottom line is you have to advance your technologies at the rate or as close to the rate of the advancement of the weapons systems that are being utilized. We’re seeing a mixture of things when it comes to the UASs; that’s larger craft that are getting faster and can carry heavier payloads, or smaller ones with longer ranges that can move through areas almost undetected. 

There’s been so much investment in UAS technology, and they are becoming cheaper and easier to manufacture. People can 3D-print these things in their houses now. So, looking at this from a sensing perspective, that layering is becoming increasingly important.

We are looking to do things to counter these developments, such as maybe elevate the sensors to “see” across the top of the trees or place a sensor down in a valley – so that adds layering in altitude or elevation to remove blind spots. Just like the military, if you’re setting-up a defensive position, you have to cover what we called “dead space” where you can’t see with eyes or sensors from ground level.

JH: Can we dig further into the role of tactical radars in counter-UAS, specifically Leonardo DRS’ 202 Expeditionary Skid, which I believe is based on your Extended Multi-Mission Hemispheric Radar [exMHR].

RB: Radars “see” things that are physically present in space and time, and that’s why they are such great tools in the counter-UAS kit bag of sensors. That said, some radars are affected by weather and other factors, some work better in particular environments.

The 202 Expeditionary Skid is a new system from Leonardo DRS that uses our long-range exMHR, which is a software-defined AESA [Active Electronically Scanned Array] pulse-Doppler radar. It operates in the S-Band and that’s a very reliable band for all weather conditions including strong performance in dust storms and rain. When you get into K, Ku, and X-bands, they typically have smaller beams and therefore greater accuracy, but they suffer in poor weather and can become extremely degraded. S-band radar suffers significantly less degradation in that environment.

The 202 Expeditionary Skid, also known as U-KIT-0091, has a single radar panel that has a search area of 90 degrees by 90 degrees, so we often mount them in groups of four to provide full 360-degree coverage. Each panel has a really fast scan rate, much faster than a traditional spinning radar set. Plus, having multiple radar faces to make up a complete system is much more survivable. They can also overlap their field of regard without impairing each other.

We have sought to provide a solution that marries an appropriate level of range, accuracy, capability, and performance, that can still be very flexible in its ability to relocate or change mission sets. This is designed to be extremely versatile, meaning that it operates in different environments quickly. U-KIT-0091 has been purposefully designed to be mobile in a compact system that can either be used by itself or networked and fused together with other systems. Back to the baseball analogy, this is the kind of guy you really want on your team because you can use them wherever you need them.

The radar or set of radars sit on a small skid system that can slide into the back of a pickup truck, into the back of a tactical vehicle, onto a trailer, you can set it just about anywhere and it occupies a four-by-four-feet position. It has its own power generation, its own positional information that works in denied environments, basically it’s capable of working by itself from the get-go. The best part is that it’s truly mobile – the operator doesn’t have to stop the vehicle to make it work. You can turn it on and set-off. It’s working. If you come to a stop, it’s still working. It can be mounted on a ship, it can be taken airborne by an aircraft, so it’s got land, sea, and air applications. We’ve installed these on all types of ground platforms, water-based platforms, on top of a building or some sort of structure and it’s already in service, but I can’t specify where. It tracks drones very well, but of course it can track just about anything that can exist in that space.

JH: So you could strategically locate several of your radars to look in different directions or be positioned to look in a certain direction if you knew the expected paths that the threats would use?

RB: The system is designed exactly for things like that. Instead of putting all of your eggs in one basket, you disperse your eggs, and focus on different avenues or approach angles so that you can then have sensors strategically located where they can pick up these things and then as long as they’re networked back into weapons systems that have the overlapping fields of fire or bubbles – coverage areas – then you can protect your area. 

Any time you can decouple a sensor from a weapon system or multiple types of sensors from each other, you stand a far greater chance of survivability and optimizing accuracy. If you put all your eggs in one basket, and if you lose that basket, you lose everything. In addition, if you separate sensors, you gain accuracy because you have different angles and you can leverage simple geometry.

JH: Could you depict what an end-to-end engagement might look like using your tactical radar.

RB: The radar sensors will typically be emitting energy as they search for objects in a particular space. If something is detected and determined to be a valid target then the data is sent from the radar to some type of a command and control system, which may well be receiving information from other complementary sensors too. It then fuses that data and passes it to an effector, whether that’s a non-kinetic or a kinetic system, for engagement.

Meanwhile, the radar continues to track and it can determine whether that object was removed or if its path changed, and so on and so forth. But you know, a lot of these radars operate in a way whereby they can be turned on or off by different sensors to avoid them having to constantly transmit energy, they’re very customizable to meet the requirements and the emissions that are needed, whether that’s air defense, counter-drone, etc.

They can operate independently too, maybe covering a small area that needs to be protected, and integrated with a localized weapon system, or, as I already explained, they can be networked into a much larger set-up, they are modular, open system architecture and easily incorporated.

Most customers tend to choose their own command and control systems, which is why the plug-and-play part of our system is so important. It really doesn’t matter what they want to partner it with, what we provide enables that very easily.

JH: To be clear, your tactical radars could be deployed to defend the entire eastern seaboard of the U.S., they could be positioned to defend an air base, or they could be used to defend a ship in the Strait of Hormuz.

RB: The architecture can scale geographically through a distributed, networked sensor approach. The specific coverage area depends on factors including sensor density, the threat environment, command-and-control integration, and the available effectors.

Customers can deploy multiple radars and feed them into a single command-and-control system, positioning sensors to optimize coverage for the operational need. For example, one radar set could cover a valley vulnerable to low-flying drone ingress, while another positioned on higher ground provides longer-range surveillance. The key is a modular capability that enables users to tailor coverage and layer sensors where they are most needed – without relying on one large radar system to see everything from a single location.

JH: I’m keen to know what you consider to be the most challenging drones to detect and track. Is the challenge the speed they’re traveling out at, maybe new low observable designs, or the fact they’re flying very low. What are the big issues you’re seeing?

RB: It’s really all of the above. The other really challenging problem is when something is flying very low to the ground. The lower they bring them in altitude, they are harder to track as an independent target.

The challenge with drone swarms isn’t detection – if you can see the drones, you can track them. The harder problem is managing those tracks, deciding which threats matter most, and assigning the right effector to each one.

If 100 drones are inbound, it’s not just about having 100 weapons available. It’s about coordinating a fast, cost-effective response across a large number of simultaneous threats.

Ultimately, pairing radars and electro-optical/infrared sensors together is the way to go, because each of those have their own strengths. One of those sensors is going to see the drone better than the other, plus you have the redundancy that at least a couple of them will “see” the threat and give you enough information in sufficient time to prosecute it. Fitting into that team, however it is constructed, is exactly how we position our 202 Expeditionary Skid U-KIT-0091 radar.

Contact the write: Jamie.Hunter@teamrecurrent.io

The post How Drone Detection Is Evolving To Counter Smaller, Faster, And Swarm Threats appeared first on TWZ.

As spades went into the ground to signal the start of construction of the new Building 47 at Lockheed Martin’s Munitions Production Center in Troy, Alabama, it marked a significant development in accelerating production of the company’s Terminal High Altitude Area Defense interceptor, better known as THAAD. The expansion of factory space in Troy is a key element of the company’s $8-9-billion commitment to expand its munitions production footprint across the United States.

The Department of War’s Acquisition Transformation Strategy is part of a long-term plan that signals clear demand for critical munitions and it enables industry to confidently invest in facilities and workforce development, along with supply chain expansion and advanced manufacturing capabilities. In addition to enlarging the facility in Troy, Lockheed Martin is also growing its plant in Camden, Arkansas, which is another site that’s vital for building more munitions at a faster pace.

“My job is to interface and collaborate with the Department of War in achieving the call to action to produce these critical munitions, not only at speed but also at scale, multiplying the current production rates by two, three, or even four times the current rates,” Dan Nimblett, Lockheed Martin’s vice president for Munitions Acceleration Integration told TWZ on the ground in Troy during the groundbreaking event.

“Fundamentally what’s occurred changes how acquisition works [with] long term demand agreements. These long term procurement agreements enable Lockheed Martin and our supply base to make the necessary investments with confidence of the future demand. This allows us to make the investments not only in our people and our facilities, but in the technology necessary to build [these munitions] at a scale and a speed that’s relevant to the threat today,” explained Nimblett.

Lockheed Martin was the first company in the U.S. defense industry to announce a framework agreement with the DoW for munitions acceleration of high-demand missiles – initially tripling production capacity of the PAC-3 Missile Segment Enhancement (MSE) interceptor, followed by a second agreement to quadruple the production capacity of advanced THAAD interceptors. These two defensive missiles are cornerstones of a layered air and missile defense system, and both have been integrated together via Joint All-Domain Operations, including with the U.S. Army’s Integrated Air and Missile Defense Battle Command System (IBCS).

In response to the DoW’s call to action, the company has already invested more than $2 billion in its production facilities and in the related tooling, its key suppliers, and its workforce in order to accelerate production rates.

Lockheed Martin plans to effectively double the factory footprint in Troy and dramatically increase the workforce. “We’re going to increase that [workforce] by drawing in college students, high school students, veterans, everybody’s welcome,” explains Jason Reynolds, vice president and general manager for integrated air and missile defense. “When they come to Lockheed Martin, they receive training, they get opportunity, and because these programs are on a ramp and in production in such high demand, this is where you come to start your career and you [can] work here for a long time.”

Lockheed Martin currently employs around 1,100 workers at its Camden site, but this is also growing. The Camden training center is seen as being critical in providing the swift increase in skilled operators needed to support this acceleration. “We work closely with the state of Arkansas as well on looking at what else we can do in the community and the infrastructure in that community to support people moving, hopefully into Camden as we ramp up,” says Reynolds.

“People here [in Troy] really know their work matters. It’s meaningful for both the community as well as for our national defense. So, we’re really proud of our employees and we’re on a growth trajectory. We’re hiring and we want as many qualified people to come join our team as possible.”

The Camden site is also accelerating its work on the long-range Precision Strike Missile (PrSM), which is also set to quadruple production over the next few years. Reynolds added that building missiles faster using automation and advanced manufacturing technologies, plus increasing the production line capacity, are some of the vital means for success.

“PAC-3 MSE and THAAD are the most capable air defense interceptors on the planet. They’re in extreme demand [and] we’re doing everything possible,” says Reynolds. “With PAC-3, we have been doubling that production over the last four years and now, like I said, we’re going to triple it. We’re working very carefully with our suppliers, with the U.S. government and with our partners and allies all around the world to get all the parts in and get them into factories like you see behind us today to assemble them and get them out to the warfighter as quickly as possible.”

Another way Lockheed Martin is accelerating the delivery of advanced air defense capabilities is the through the introduction this summer of the PAC-3 Adapted Capability Effector, or PAC-3 ACE. This new missile leverages the PAC-3 fire-control system and provides for full integration with the Patriot weapon suite.

The main differentiator of PAC-3 ACE is that it would be produced at less than half the unit cost of MSE and first flight could occur within 18 months. A core part of the rapid fielding strategy is an international, joint-development model. Lockheed Martin is partnering with both American and European industry, sharing production lines, supply chains and expertise.

Lockheed Martin says PAC-3  ACE provides a “cost-effective, multi-threat solution.” The interceptor is engineered to engage a broad spectrum of air-breathing threats, cruise missiles, and both short and medium-range ballistic missiles. By offering a low-cost “kill” per-engagement, it is designed to address the current climate that demands deeper ammunition reserves without compromising on performance.

The keys to munitions acceleration

This year, Lockheed Martin has made significant progress in a series of production acceleration projects for munitions programs under its Missiles and Fire Control division. “I was supposed to retire last year. I’m here because this is the most exciting time in the 30 years I’ve been in this industry,” says Dan Nimblett. “These long-term agreements provide us the certainty to enable us to make these investments.”

“What recent conflicts have demonstrated is that Lockheed Martin and the American defense industrial base never lost the technological edge. The technology and the capability has always been there – we have the best systems in the world. We’ve proven that through real world performance.”

Nimblett explained that Lockheed Martin’s supply chain is following suit, and that they are all now investing in similar ways to ensure they meet the demand signals. “We’re evaluating how we produce and increase additive manufacturing and robotics. We’re also looking at how we develop, which I think is a fundamental part of getting capability into the warfighters’ hands at a speed and scale that’s relevant to the threat.”

Having received Milestone C approval from the U.S. Army in July 2025, PrSM manufacturing has relied on a high level of automation. PrSM was engineered from the start for automated, robot-driven production – automating tasks once done by hand – and that early-stage streamlining is paying dividends as Lockheed Martin seeks to accelerate output.

“We have a lot of robotics built into our munitions production,” explains Gaylia Campbell, vice president, Tactical Missiles. “A lot of times we use robotics to help increase the safety of the assembly, like an explosive charge that has to be integrated into a munition, and we have a robotic arm that places that and tests the placement. We also robotically paint and coat [PrSM]. So, we have a lot of robotics already in Camden and that’s really going to help us with this ramp-up in production – the fact that so much of it is [already] automated.”

Campbell emphasizes that PrSM entered production with a mindset of acceleration. “We got PrSM through preliminary and critical design reviews, and into first flight in times roughly half of what it would normally have taken us. We’ve been amazingly successful on all these flights. Those early [test] flights went off one after the other during the COVID-19 pandemic, at a time when there were a lot of challenges for all of us in our daily lives, and yet we were able to continue to fly and prove the operational performance.”

Lockheed Martin is reshaping the munitions supply chain with an unprecedented slate of manufacturing initiatives that pull together new facilities, strategic partnerships, and workforce development. The company is also expanding a number of its other production facilities, such as a $60-million investment in its complex in Archbald, Pennsylvania, that will add 700 jobs in support of high‑priority programs including PrSM, THAAD, PAC‑3, and Apache sensors. In Orlando, Florida, three legacy paint bays have been merged into a high‑performance shop that can retool a work cell in hours rather than weeks, while Ocala’s new Progressive Work Smart Assembly Line has cut seeker and mission control unit build times by roughly 50 percent.

A partnership with General Motors will bring high‑rate commercial manufacturing expertise into Lockheed Martin’s production processes, and the new Rapid Fielding Center in Grand Prairie, Texas, is tasked to reduce traditional manufacturing development timelines. What once took years of design, testing and tooling is aimed to be prototyped, fabricated and validated in a matter of months.

Echoing endorsement of the DoW’s initiative, Campbell underscores that knowing what the demand signal will be is a critical differentiator when it comes to production ramp-up. “We can plan for some of those really critical rare earth minerals that we need, the batteries for example in our munitions, we need certain rare earth minerals for that. We need to know the total demand signal and that means we can negotiate with the suppliers and guarantee that we have access. That can really help us accelerate.”

To support the wider munitions efforts Lockheed Martin is also investing in solid rocket motor development and production, as well as lower-tier parts that go into solid rocket motors. “We’re working with different suppliers to develop new sources of supply for solid rocket motors,” says Campbell. “We’re investigating heavily right now in designing and prototyping several motors that we plan to test and take to production, and that really will develop a whole new supply chain and will really be critical for all munitions production.”

Having a five-year contract instead of annual contracts allows the manufacturer to have far more buying power to secure sub-components for a far better price point. “I can go and invest. Invest in more capacity, invest in my supplier’s capacity,” explains Campbell.

“Production is all about velocity. Keeping the line moving and not having to stop because we don’t have a part. Being able to order bigger quantities of things up front is really huge when it comes to acceleration.”

Contact the author: Jamie.Hunter@teamrecurrent.io

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