Preparing the U.S. Industrial Base for Large-Scale Manufacturing of Small-To Medium-Sized Unmanned Surface Vessels

Abstract

The U.S. Navy’s Hybrid Fleet concept and the DoD’s demand for attritable unmanned systems require a domestic industrial base capable of rapidly producing small- to medium-sized unmanned surface vessels (USVs). This thesis hypothesizes that current U.S. manufacturing capacity, shaped by foreign component dependence, workforce shortages, and fragmented production infrastructure, is insufficient to scale USV output to operational requirements. The study uses a mixed-methods approach, including a historical review of industrial mobilization, Bill of Materials (BOM) risk scoring, North American Industry Classification System (NAICS) labor force analysis, and industry engagement. Results indicate significant constraints in electronics and energy components, limited surge capacity among U.S. manufacturers, and acquisition timelines that do not incentivize scalable production. The thesis concludes that the U.S. has several challenges that it must address now to ensure that future USV demands are met. Key recommendations include domestic investment in high-risk components, expanding the workforce pipeline, implementing modular production lines, improving supply chain visibility, and synchronizing government furnished payload to vessel acquisition timelines.