Inside the Drone Manufacturing Challenge: Scaling What Matters

Summary
Re:Build’s Drone Thesis Leader joins The Drone Ultimatum podcast to discuss scaling U.S. drone production from design to manufacturing.

Re:Build Manufacturing’s Drone Thesis Leader, David Michelson, recently joined The Drone Ultimatum podcast to discuss one of the most pressing challenges in defense and hard tech today: how to actually build drones at scale in the United States.

David brings a unique perspective to the conversation. A former Army Ranger with multiple deployments and the former Director of Autonomy at the Defense Innovation Unit (DIU), he now leads Re:Build’s efforts to develop scalable, U.S.-based drone manufacturing capabilities from initial design through full-rate production.

In this discussion, David explores the realities behind the headlines:

  • Why scaling drone production is fundamentally a manufacturing challenge, not just an engineering one
  • How lessons from real-world conflicts are shaping the future of autonomy and defense technology
  • The gaps in standardization that continue to slow progress across the drone industry
  • Why designing for manufacturability from the outset is critical to success
  • How Re:Build is helping bridge the gap between innovative design and reliable production

As demand for drones continues to accelerate, one issue is becoming increasingly clear: many companies can design compelling products, but far fewer can produce them at the scale required.

At Re:Build, we’re focused on solving that problem, bringing together design, engineering, supply chain, and manufacturing expertise to enable scalable production of complex systems.

Watch the full conversation to hear David’s insights on where the industry is headed and what it will take to build the next generation of drone capabilities. 

Heading to Xponential 2026? Re:Build Manufacturing will be there connecting with innovators across the unmanned systems and autonomy ecosystem.

Don’t miss David Michaelson’s presentation, “Refocused Purpose – Drone as a Platform for Fueling Innovation,” on Thursday, May 14 at 2:00 PM in the Innovation Theater.

Learn more about what we’ll be showcasing at the event: 

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