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U.S. Defense Firms Reengineer Missiles to Cut Cost and Speed Production

Simpler missile seekers are being introduced to stretch thin interceptor stocks.

Overview

  • Major contractors told defense officials at the Huntsville Space and Missile Defense Symposium that they are redesigning interceptors to be cheaper and faster to build by simplifying components and production steps.
  • Boeing says it has flight-tested an "ultra low cost" seeker that uses commercial-grade parts to reduce the seeker's share of missile cost from about 30% to roughly 10% and that it plans an intercept test next year, a company-provided plan that has not yet produced a confirmed intercept.
  • Lockheed Martin has unveiled the Patriot ACE, an adaptation of the PAC-3 offered at about $2 million a unit that sacrifices some range and precision to speed manufacture and lower price compared with the roughly $4 million PAC-3 MSE.
  • The Pentagon has started awarding work to smaller firms such as Castelion, Anduril, CoAspire and Zone 5 to broaden supply, but officials say final production depends on definitive contracts, congressional emergency appropriations, and resolving supply-chain limits.
  • Industry and Pentagon analysis warn that chokepoints—two-pulse solid rocket motors, high‑precision seekers, and a shortage of specialized manufacturing labor—mean meaningful stockpile recovery will take years and require capability trade-offs for forces and partners.