Red Cat Holdings has formed a strategic partnership between its maritime division, Blue Ops, and HADDY to integrate large-scale robotic 3D printing into its unmanned surface vessel (USV) production lines.
The collaboration will equip the Blue Ops facility in Valdosta, Georgia, with Agentic AI-powered robotic production systems. This move is expected to double the overall manufacturing capacity for the company’s line of unmanned surface vessels (USVs), including both 5-meter and 7-meter variants. By utilizing a microfactory approach, the partnership aims to streamline the design and delivery process, moving away from traditional shipbuilding methods in favor of faster, more flexible additive manufacturing.
“This partnership advances our ability to iterate at the speed of modern conflict,” said Barry Hinckley, President of Blue Ops. “This also underscores a shift in how boats are built. The industry has seen moments like this when fiberglass replaced wood, and we’re seeing a similar transition now with large-scale 3D printing. This fundamentally changes how quickly we can move from concept to deployment and gives us the ability to meet demand at scale in ways the industry hasn’t seen before.”
Hinckley also noted that the choice to partner with HADDY was influenced by the company’s approach to technical security; “Another critical reason Blue Ops decided to partner with HADDY is our confidence in how the company prioritizes high-level data and IP protection, which is non-negotiable in an industry like ours.”
The production transition involves using robotic systems supported by AI models that learn and adapt during the manufacturing process. This allows engineering teams to prototype and iterate designs with fewer delays compared to standard industrial timelines. Beyond the Valdosta site, Blue Ops will gain access to HADDY’s broader network of distributed microfactories. This scalable model allows production to be shifted or expanded based on global operational needs, positioning vessels closer to their eventual deployment zones.
“Manufacturing is moving toward a more distributed and scalable model, and large-scale robotic 3D printing is a key part of that shift,” said Jay Rogers, Co-founder and CEO at HADDY. “By combining production technology with a global microfactory network, we can build complex systems more efficiently and closer to where they are needed. Blue Ops is early in applying this approach to maritime systems, and it has the potential to reshape how these platforms are produced and deployed.”
As a provider of advanced all-domain robotic solutions for defense and national security, Red Cat is utilizing this partnership to strengthen domestic manufacturing capabilities. The integration of 3D printing technologies is designed to ensure that critical maritime systems can be produced at scale to meet the requirements of both national and allied defense missions without the constraints of traditional manufacturing bottlenecks.
