IP Library Granted Patent US 12,371,198
Granted Patent B1
US 12,371,198 · App. 19/066,080 · Granted Jul 29, 2025

Mission-adaptable aerial vehicle and methods for in-field assembly and use

Inventors: Ian Muceus (San Diego, CA); Daniel Magy (San Diego, CA)
Assignee: Firestorm Labs, Inc.
B64U10/70B64U20/75B64U20/87B64U2201/104
View Patent ↗
Loading inventors, assignments & file history…
Monitor This Case
Get email alerts when status or documents change.
Order Certified Copies
Most orders are placed with the USPTO same day — all within 24 business hours.
Order via The Patent Place →
Pre-filled with this patent's details
Quick Facts
Patent No.
US 12,371,198
App. No.
19/066,080
Granted
Jul 29, 2025
Kind
B1
Abstract

Disclosed are devices, systems and methods for mission-adaptable aerial vehicle. In some aspects, a mission-adaptable aerial vehicle includes a configuration having swappable, manipulatable, and interchangeable sections and components connectable by a connection and fastening system able to be modified by an end-user in the field. In some embodiments, a mission-adaptable aerial vehicle can be configured to include a main center body extending along a longitudinal direction, a wing with a lateral cross-sectional airfoil shape, and/or stabilizer and control surface structures with corresponding cross-sectional airfoil shapes.

Claims (23)

1. A method for facilitating in-field assembly of a mission-adaptable aerial vehicle, the method comprising:

providing a user interface via a software application on a mobile device associated with a a user, wherein the user interface includes a display screen presenting details of an aircraft a and a list of available sections and/or components associated with the aircraft of the mission-adaptable aerial vehicle;

receiving an input from the user interface associated with a selection of at least one or some of the available sections and/or components to include in an assembly of the mission-adaptable aerial vehicle;

producing one or more assembly protocols including instructions to assemble the mission-adaptable aerial vehicle for an in-field assembly procedure; and

generating, in real-time of the in-field assembly procedure, a modification scheme to cause a change in the instructions based on a determined change in one or more of flight dynamics, flight stability, or flight control of the mission-adaptable aerial vehicle.

2. The method of claim 1 , wherein the determined change includes one or more of: an environmental factor including a temperature, pressure, or weather forecast or measurement; a mission factor including a target location, a launch location, a trajectory parameter, or an altitude parameter; or a temporal factor including a time window of assembly or a time window of a mission.

3. The method of claim 1 , wherein the instructions include information on how the user modifies elements, including at least one of wing placement, a control surface sizing, a powerplant output or thrust, or one or more parameters to accommodate a change in a weight, a a fuselage length, an added or reduced drag, and/or a powerplant.

4. The method of claim 1 , wherein the user interface includes a touchscreen interface to allow the input to include one or more of a tap, a drag, or a dropdown.

5. The method of claim 1 , wherein the mission-adaptable aerial vehicle comprises:

a fuselage assembly comprising one or more fuselage sections;

a wing assembly attachable to the fuselage assembly, the wing assembly including one or more wing sections;

a nose cone assembly attachable to the fuselage assembly, the nose cone assembly including one or more nose cone sections;

a tail assembly attachable to the fuselage assembly, the tail assembly including one or more tail sections;

a propulsion unit at least partially contained in at least one of the tail assembly or the fuselage assembly and configured to drive flight of the mission-adaptable aerial vehicle; and

an electronics unit comprising a wireless transceiver device.

6. The method of claim 5 , wherein the generated modification scheme causes a change in the instructions to a number of fuselage sections for the fuselage assembly based on the determined change in one or more of the flight dynamics, the flight stability, or the flight control of the mission-adaptable aerial vehicle.

7. The method of claim 5 , wherein the generated modification scheme causes a change in the instructions to a number of wing sections for the wing assembly based on the determined change in one or more of the flight dynamics, the flight stability, or the flight control of the mission-adaptable aerial vehicle.

8. The method of claim 5 , wherein the generated modification scheme causes a change in the instructions to a number of tail sections for the tail assembly based on the determined change in one or more of the flight dynamics, the flight stability, or the flight control of the mission-adaptable aerial vehicle.

9. The method of claim 5 , wherein at least one fuselage section of the fuselage assembly and at least one tail section of the tail assembly each comprise a body portion having a curved wall and either (i) one or more protrusion structures integrally part of and spanning from the curved wall or (ii) one or more slots disposed in a portion of the curved wall, wherein the one or more protrusion structures is integrally formed of a same material structure as the curved wall of the at least one fuselage section or the at least one tail section, and wherein the portion having the one or more slots is formed of a same material structure of the curved wall as the other one of the at least one fuselage section or the at least one tail section.

10. The method of claim 9 , wherein one or both of (i) the one or more protrusion structures and (ii) the one or more slots includes one or more holes to align with corresponding one or more holes of the other of the of (i) the one or more protrusion structures or (ii) the one or more slots.

11. The method of claim 9 , wherein one or both of (i) the one or more protrusion structures and (ii) the one or more slots includes one or more projections to align with corresponding one or more holes of the other of the of (i) the one or more protrusion structures or (ii) the one or more slots.

12. The method of claim 1 , wherein the one or more assembly protocols include instructions to 3D-print the mission-adaptable aerial vehicle for the in-field assembly procedure.

13. The method of claim 1 , wherein the in-field assembly procedure allows for an in-the-field change to one or more components of the mission-adaptable aerial vehicle at a location where the mission-adaptable aerial vehicle is to take off.

Assignments (2)
SECURITY INTEREST Recorded Jul 18, 2025
From: FIRESTORM LABS, INC.
To: JPMORGAN CHASE BANK, N.A.
Reel/Frame 071763/0195 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Feb 27, 2025
From: MUCEUS, IAN; MAGY, DANIEL
To: FIRESTORM LABS, INC.
Reel/Frame 070357/0584 →
Continuity (7)
Continuation 18936906 · Nov 4, 2024
Continuation 18655221 · May 3, 2024
Continuation 18510592 · Nov 15, 2023
Continuation In Part PCTUS2023022151 · May 12, 2023
Provisional Application 63429506 · Dec 1, 2022
Provisional Application 63366119 · Jun 9, 2022
Provisional Application 63341647 · May 13, 2022
References Cited (157)
US 2019652A · Brookley · 1935 [cited by examiner]
US 3218005A · Calderon · 1965 [cited by examiner]
US 6065720A · Ash · 2000 [cited by examiner]
US 8068949B2 · Duggan · 2011 [cited by examiner]
US 8068950B2 · Duggan · 2011 [cited by examiner]
US 8082074B2 · Duggan · 2011 [cited by examiner]
US 8103398B2 · Duggan · 2012 [cited by examiner]
US 8355834B2 · Duggan · 2013 [cited by examiner]
US 8380425B2 · Duggan · 2013 [cited by examiner]
US 8700306B2 · Duggan · 2014 [cited by examiner]
US 8768555B2 · Duggan · 2014 [cited by examiner]
US 8882560B2 · Sofman · 2014 [cited by examiner]
US 9108729B2 · Duggan · 2015 [cited by examiner]
US 9254363B2 · Levien · 2016 [cited by examiner]
US 9555873B1 · Alley · 2017 [cited by examiner]
US 9713675B2 · Levien · 2017 [cited by examiner]
US 10767624B2 · Monreal Lesmes · 2020 [cited by examiner]
US 11027584B1 · Kiceniuk, Jr. · 2021 [cited by examiner]
US 11187203B2 · Badger · 2021 [cited by examiner]
US 11358700B1 · Poe · 2022 [cited by examiner]
US 11450233B2 · Becker · 2022 [cited by examiner]
US 11521512B2 · Marquinez Torrecilla · 2022 [cited by examiner]
US 11597490B1 · Gundlach · 2023 [cited by examiner]
US 11721231B2 · Becker · 2023 [cited by examiner]
US 11981460B2 · Muceus · 2024 [cited by examiner]
US 12139280B2 · Muceus · 2024 [cited by examiner]
US 12202634B1 · England · 2025 [cited by examiner]
US 12236494B1 · Melgar · 2025 [cited by examiner]
US 12240634B1 · Muceus · 2025 [cited by examiner]
US 20080149758A1 · Colgren · 2008 [cited by examiner]
US 20090026321A1 · Sarh · 2009 [cited by examiner]
US 20090166477A1 · Bousfield · 2009 [cited by examiner]
US 20100159434A1 · Lampotang · 2010 [cited by examiner]
US 20100178966A1 · Seydoux · 2010 [cited by examiner]
US 20110036939A1 · Easter · 2011 [cited by examiner]
US 20110130913A1 · Duggan · 2011 [cited by examiner]
US 20110221692A1 · Seydoux · 2011 [cited by examiner]
US 20120123628A1 · Duggan · 2012 [cited by examiner]
US 20130345920A1 · Duggan · 2013 [cited by examiner]
US 20140025229A1 · Levien · 2014 [cited by examiner]
US 20140234116A1 · Cussac · 2014 [cited by examiner]
US 20140324253A1 · Duggan · 2014 [cited by examiner]
US 20150003991A1 · Bagepalli · 2015 [cited by examiner]
US 20150292477A1 · Kratmann · 2015 [cited by examiner]
US 20160121992A1 · Saroka · 2016 [cited by examiner]
US 20160129984A1 · Tiryaki · 2016 [cited by examiner]
US 20170008611A1 · Murta · 2017 [cited by examiner]
US 20170066135A1 · Cohen · 2017 [cited by examiner]
US 20170152014A1 · Gould · 2017 [cited by examiner]
US 20170185081A1 · Steele · 2017 [cited by examiner]
US 20170253316A1 · Benthien · 2017 [cited by examiner]
US 20170349281A1 · Quinlan · 2017 [cited by examiner]
US 20180067476A1 · Engelbart · 2018 [cited by examiner]
US 20180104863A1 · Cottrell · 2018 [cited by examiner]
US 20180162540A1 · Iliopoulos · 2018 [cited by examiner]
US 20180273158A1 · Courtin · 2018 [cited by examiner]
US 20180297698A1 · Dhall · 2018 [cited by examiner]
US 20180312252A1 · Yates · 2018 [cited by examiner]
US 20180334248A1 · Neiser · 2018 [cited by examiner]
US 20180355842A1 · Badger · 2018 [cited by examiner]
US 20190051051A1 · Kaufman · 2019 [cited by examiner]
US 20190077098A1 · Riley · 2019 [cited by examiner]
US 20190077496A1 · Livieratos · 2019 [cited by examiner]
US 20190106192A1 · Woodworth · 2019 [cited by examiner]
US 20190106195A1 · Wilkerson · 2019 [cited by examiner]
US 20190135403A1 · Perry · 2019 [cited by examiner]
US 20190143596A1 · Fiechter · 2019 [cited by examiner]
US 20190193829A1 · Schlueter · 2019 [cited by examiner]
US 20190224909A1 · Riha · 2019 [cited by examiner]
US 20190255777A1 · Fiechter · 2019 [cited by examiner]
US 20190322032A1 · Riha · 2019 [cited by examiner]
US 20190322047A1 · Riha · 2019 [cited by examiner]
US 20190374868A1 · Russell · 2019 [cited by examiner]
US 20190381530A1 · Beaudoin · 2019 [cited by examiner]
US 20190389555A1 · Guering · 2019 [cited by examiner]
US 20200032665A1 · Propheter-Hinckley · 2020 [cited by examiner]
US 20200047867A1 · Griess · 2020 [cited by examiner]
US 20200180760A1 · Richardson · 2020 [cited by examiner]
US 20200188732A1 · Kruger · 2020 [cited by examiner]
US 20200216196A1 · Sohmshetty · 2020 [cited by examiner]
US 20200247561A1 · Rivera · 2020 [cited by examiner]
US 20200310408A1 · Carper · 2020 [cited by examiner]
US 20200407039A1 · Sanders · 2020 [cited by examiner]
US 20210031912A1 · Yates · 2021 [cited by examiner]
US 20210046694A1 · Rowe · 2021 [cited by examiner]
US 20210070419A1 · Decker · 2021 [cited by examiner]
US 20210082304A1 · Daley · 2021 [cited by examiner]
US 20210174695A1 · Clark · 2021 [cited by examiner]
US 20210232873A1 · Kothari · 2021 [cited by examiner]
US 20210256875A1 · Mosier · 2021 [cited by examiner]
US 20210331789A1 · Wardlaw · 2021 [cited by examiner]
US 20210347462A1 · Haack · 2021 [cited by examiner]
US 20210372366A1 · Merzhaeuser · 2021 [cited by examiner]
US 20210403143A1 · Alley · 2021 [cited by examiner]
US 20220017204A1 · Helou, Jr. · 2022 [cited by examiner]
US 20220111956A1 · Jordan · 2022 [cited by examiner]
US 20220152758A1 · Jones · 2022 [cited by examiner]
US 20220153452A1 · Smith · 2022 [cited by examiner]
US 20230192267A1 · Gundlach · 2023 [cited by examiner]
US 20240092510A1 · Muceus · 2024 [cited by examiner]
US 20240185736A1 · Prodzenko · 2024 [cited by examiner]
US 20240294279A1 · Muceus · 2024 [cited by examiner]
US 20240339046A1 · Paull · 2024 [cited by examiner]
US 20240371290A1 · Kane · 2024 [cited by examiner]
US 20250021101A1 · Koch · 2025 [cited by examiner]
US 20250026506A1 · Robbins-Rothman · 2025 [cited by examiner]
US 20250033809A1 · Jiang · 2025 [cited by examiner]
US 20250058904A1 · Muceus · 2025 [cited by examiner]
US 20250108943A1 · Sekiguchi · 2025 [cited by examiner]
US 20250153871A1 · Liu · 2025 [cited by examiner]
US 20250155785A1 · Tian · 2025 [cited by examiner]
CN 102923296A · 2013 [cited by applicant]
CN 105771269A · 2016 [cited by applicant]
CN 106671402A · 2017 [cited by applicant]
CN 112061372A · 2020 [cited by applicant]
CN 112158323A · 2021 [cited by applicant]
EP 3525259A1 · 2019 [cited by applicant]
FR 3025491A1 · 2014 [cited by applicant]
FR 3109369A1 · 2020 [cited by applicant]
IN 201941005768 · 2019 [cited by applicant]
WO 2019125159A1 · 2019 [cited by applicant]
WO 2019212553A1 · 2019 [cited by applicant]
WO 2020264115A1 · 2020 [cited by applicant]
International Application No. PCT/US2023/022151 International Search Report and Written Opinion mailed Dec. 27, 2023, pp. 1-17. [cited by applicant]
AMRC Design and Prototyping Group, “Rapid Manufactured Fixed Wing Powered UAV”, Case Study, 11 page (s), UK. [cited by applicant]
AMRC Design and Prottyping Group, “FDM Printed Fixed Wing UAV”, Case Study, 7 pages, UK. [cited by applicant]
Eric Tegler, “UAS Startup Firestorm's Ambition to Crank Out Combat Drones Fast, Cheap and En Masse Is a Lesson for DoD”, article, Apr. 27, 2023, 6 pages, US. [cited by applicant]
Scott Sevcik, “Where's the real value in additive?—An AM Perspective (Part 2)”, LinkedIn Article, Dec. 5, 2022, 5 pages, US. [cited by applicant]
David D. North, Ronald C. Busan, and Greg Howland, “Design and Fabrication of the Langley Aerodrome No. 8 Distributed Electric Propulsion VTOL Testbed”, Journal, 19 pages, US. [cited by applicant]
De Vivo Nicoloso and Luca Gabriele, “Data driven systems engineering for bioinspired integrative design” peer reviewed thesis/dissertation, 2021, 240 pages, San Diego, CA, US. [cited by applicant]
Troy McMillan, “How to build Exlipson Model V—RC 3D Printed Airplane” YouTube Video, Feb. 25, 2021, 7 pages. [cited by applicant]
Robert M. Taylor, Nicholas Lira, Gavin Sabine, Joakim Lea, Craig Conklin, Bijan Niakan, and Sangram Advirkar, “Design Optimization, Fabrication, and Testing of a 3D Printed Aircraft Structure Using Fused Deposition Mode… [cited by applicant]
Aaron Pearson, “World's first jet-powered, 3D printed UAV tops 150 mph with lightweight Stratasys materials” blog, Mar. 24, 2020, 3 pages, Stratasys.com. [cited by applicant]
Akhilesh Kulkarni, “Static Response Calibration of 3D Printed Thin Walled Structures Using Fused Deposition Modelling” Thesis/Dissertation, Dec. 2019, 63 page(s), Arlington, TX, US. [cited by applicant]
Luca De Vivo, Danny Tran, and Falko Kuester, “Towards Design of a 3D Printable Prandil Box-Wing Unmanned Aerial Vehicle”, 2018, 17 pages, CISA3 DroneLab Jacobs School of Engineering. [cited by applicant]
Kelsey Muller, “Flying from Protoypring to Mainstream: 3D Printed Aircrafts Top Out at Speeds of 150mph”, Technology and Operation Management MBA Student Perspectives Assignments, Nov. 12, 2018, 2 pages. [cited by applicant]
Henry Tucher, “How U.S. Marine Rhet McNeal Designed a 3D Printable Drone to Cost 200X Less at Autodesk's Pier 9” Autodesk News Article, Aug. 22, 2017, 5 pages. [cited by applicant]
Zhuo Wei Wong, Yunus Govoelli, and Erdal Kayacan, “Additive Manufacturing of Unmanned Aerial Vehicles: Current Status, Recent Advances, and Future Perspectives”, 2016, 11 pages, Research Publishing, Singapore. [cited by applicant]
Daniel O'Connor, “Game of Drones”, TCT Magazine, Feb. 29, 2016, 8 pages. [cited by applicant]
G.D. Goh, S. Agarwala, G.L.. Goh, V. Dikshit, S.L. Sing, and W.Y. Yeong, “Additive manufacturing in unmanned aerial vehicles (UAVs) Challenges and potential”, Aerospace Science and Technology Forum, Aug. 26, 2016, 12 pa… [cited by applicant]
Robert P. Dahlgren, Juan J. Alonso, and Matthew M. Fladeland, “Progress on Modular Unmanned Aircraft Technology”, ASPRS 3rd UAS Symposium, Sep. 12-14, 2016, 25 pages. [cited by applicant]
Chris Banfield, James Kidd, and Jamey Jacob, “Design and Development of a 3D Printed UAV”, Aerospace Science and Technology Forum, Jan. 4-8, 2016, 19 pages. [cited by applicant]
Newco, “Local Motors: Driving Innovation with Micro-Manufacturing”, Medium Magazine Article, Oct. 12, 2016, 21 pages. [cited by applicant]
Aurora Flight Sciences, “Aurora Successfully Flies Subscale X-Plane Aircraft” YouTube Video, Apr. 18, 2016, 1 page. [cited by applicant]
University of Virginia, “The Razor: UVA's 3D-printed U.A.V.”, YouTube Video, Aug. 29, 2014, 1 page. [cited by applicant]
Press, “Aurora Flight Sciences 3D printed wing”, sUAS News the business of drones Article, Nov. 9, 2015, 4 pages. [cited by applicant]
Pedro Santos, Joaquim Sousa, and Pedro Gamboa, “Variable-span wing development for improved flight performance ” Journal of Intelligent Material Systems and Structures, 2015, 18 pages. [cited by applicant]
S. Palanivel, H. Sidhar, and R.S. Mishra, “Friction Stir Additive Manufacturing: Route to High Structural Performance”, Article in JOM: the journal of the Minerals, Metals & Materials Society, Jan. 13, 2015, 7 pages, vo… [cited by applicant]
Michael Molitch-Hou, “Feasibility of Hovering Aircraft Demonstrated with 3D Printing”, web article, May 4, 2016, 4 pages. [cited by applicant]
Businesswire a Berkshire Hathhaway Company, “Aurora Flight Sciences and Stratasys Deliver World's First Jet-Powered, 3D Printed UAV in Record Time”, Nov. 9, 2015, 3 pages. [cited by applicant]
Christipher P. Banfield, “Design and Development of a 3D Printed UAV”, The 2015, 160 pages, volume-issue number(s), publisher, city and/or country where published. [cited by applicant]
Mario Ferraro, Andrew Lock, James P. Scanlan, and Andy J. Keane, “Design and flight test of a civil unmanned aerial vehicle for maritime patrol: the use of 3D-printed structural components”, 14 pages. [cited by applicant]
Carl Muldal, Edward Kolb, Graham Robertson, Aaron Parkinson, Osvaldo M. Querin, Robert W. Hewson and Vassili V. Toropov, “The use of MDO and Advanced Manufacturing to Demonstrate Rapid, Agile Construction of a Mission O… [cited by applicant]
Joe Hiemenz, “Additive Manufacturing Trends”, Stratasys Article, 11 pages. [cited by applicant]
Steven Easter, Jonathan Turman, David Sheffler, Michael Balazs, and Jonathan Rotner, “Using Advanced Manufacturing to Produce Unmanned Aerial Vehicles: A Feasibility Study”, May 22, 2013, 17 pages. [cited by applicant]
N.A. Ahmed and J.R. Page, “Manufacture of an Unmanned Aerial Vehicle (UAV) for Advanced Project Design using 3D Printing technology”, 2013, 11 pages, vols. 397-400, pp. 970-980, Applied Mechanics and Materials. [cited by applicant]
UVAToday, “Student Engineers Design, Build, Fly ‘Printed’ Airplane”, Web Article, Oct. 5, 2012, 4 pages. [cited by applicant]