Australian firm launches 3D-printed defence USV

A deployable TitanCell 3D printing system building a Astra 460 USV hull. (Hyperion Systems)

Perth-based Hyperion Systems has launched a 3D-printed unmanned surface vehicle (USV) for defence applications at the Indian Ocean Defence and Security (IODS) conference, held by the Western Australia government from 26 to 28 May.

Hyperion Systems announced on 26 May that this 4.6 m USV, called Astra 460, will be built at its Henderson facility in Western Australia using recycled polymer waste and large-format additive manufacturing (LFAM), which enables faster, more cost-effective production.

Astra 460 project manager Jacob Kleinman said the USV can support border protection and intelligence, surveillance and reconnaissance (ISR) operations.

A company spokesperson told Janes that a key advantage of Astra 460 is its “rapid build, which provides the ability to customise for specific payloads or mission use cases within 40 hours”. The USV is made from high-density polyethylene (HDPE), making it a tough, and impact-resistant platform, the spokesperson said.

The spokesperson said that Hyperion's 3D printing process does not depend on foreign supply chains, ensuring faster deliveries. “Hyperion specialises in 3D printing technology outside of a cubic metre using polymer extrusion technology that can print large parts rapidly and robotically. The materials are derived from many different streams of plastic waste.

“The core research and development (R&D) focus over the last 6-12 months has been on converting industrial waste into feedstock for the machines. This is critical for sovereign supply chain strength as it doesn't rely on overseas imports,” the spokesperson added.

Sea trials of Astra 460 will commence in June, the spokesperson said, adding that Hyperion intends to demonstrate the USV to the Australian Defence Force (ADF) over the coming months.