Drones are rapidly transforming military and governmental operations. Daily news reports, for instance, underscore their significance in the conflict in Ukraine, where both Russian and Ukrainian forces deploy drone-based attacks. Military drones vary in size, from bird-like handheld units to unmanned aerial vehicles (UAVs) capable of transporting heavy payloads. In this highly contested airspace, neither side has established air superiority. Drones have become indispensable in defense missions, and their application extends to government assignments, including law enforcement. As reliance grows on drones, so does the demand for advanced, integrated electronic systems.
Advancements of Military Drones in Modern Warfare
Large drones perform critical operations, such as transporting weapons and surveillance equipment, and may even transport troops in the future. Smaller drones perform more tactical engagements on the battlefield. For example, handheld-sized drones can navigate complex environments, carrying instruments, munitions, and supplies necessary for commanders to make quick tactical decisions. Equipped with cameras, microphones, and sensors, these specialized drones collect data on missions deemed too dangerous to send in troops. Integrated with Electronic Warfare (EW) systems, the drones can conduct Intelligence, Surveillance, and Reconnaissance (ISR) missions. Smaller drones require compact, integrated electronic equipment, including Command and Control (C2) and Command, Control, and Communications (C3) systems.
Traditionally, these smaller drones are piloted remotely from a distance typically around 5 km or less (3.1 miles), relying on C2 or C3 radio links between the drone and the remote controller—often a ground control station (GCS). These radio links are often maintained within unlicensed frequency bands, such as 35 MHz, or unlicensed industrial-scientific-medical (ISM) frequency bands at 2.4 and 5 GHz. Direct radio links between a controller and drone facilitate navigation and surveillance, helping to avoid obstacles such as trees and buildings in the flight path. A direct radio link with sufficient bandwidth can transmit data and video from the drone to the controller. However, for longer distances, other wireless technologies are necessary. Access to mobile communications networks—such as 5G or satellite communications (SATCOM) systems—enables longer C2/C3 links between the drone and the operator.
Maintaining a C2/C3 link between a drone and its controller is critical for mission success on the battlefield. Benchmark's engineers have collaborated with drone developers to maintain communications and control under adverse conditions. For example, despite often limited payload size, Benchmark's engineers have developed redundant communication links across various frequencies to counter jamming and other adversarial communications disruptions. Our engineers have also developed circuits with fail-safe modes, automatically triggered by the loss of a C2/C3 signal, and compact anti-jamming equipment that can be readily integrated into small drone payloads.
Addressing Vulnerabilities—EM Shielding and Anti-Jamming
While under radio control, drones are vulnerable to interference from jammers and high-frequency signals, which can disrupt drone control and C2/C3 access. Defense drone developers equip drones with electromagnetic (EM) shielding and anti-jamming circuits to counter such interference. In the event of C2/C3 access loss, drones can respond by hovering in place, landing at the point of disconnection, or activating a "return-to-home" (RTH) function, guiding the aircraft back to its starting point.
As smaller drones are deployed for longer missions and extended operating times, energy efficiency and the size and weight of the payloads become more critical. Reduced size, weight, and power (SWaP) are essential and will continue to be more critical as smaller drones are tasked with more functions and extended flight times. By utilizing integrated circuits (ICs), system-in-package (SiP) devices, and system-on-chip (SoC) solutions, manufacturers can save space and reduce power consumption, meeting the demand for denser circuits with lower power usage.
Some design solutions can be expensive, putting them at odds with cost targets for smaller battlefield drones intended for deployment by the thousands. The U.S. Department of Defense (DoD) is exploring these tradeoffs by engaging with drone developers pursuing different approaches. Some of the drones being tested are like miniature versions of other defense aircraft, while others are closer to commercial models that deliver unique capabilities using software. As DoD awards these contracts, the most likely outcome is that a strategy will emerge that leverages a combination of approaches and capabilities depending on the exact application.
Compact Payloads
Flight time is a differentiating parameter for combat and other drones, significantly influenced by payload weight. Drone system engineers can maximize flight time and range by minimizing drone payload, optimizing SWaP, and enhancing the power efficiency of electronic systems. As smaller drones are developed for defense applications, electronics miniaturization is critical in achieving the reduced SWaP necessary for longer travel distances and flight durations.
Benchmark's design engineering team works with drone developers to optimize SWaP-C and extend a drone's capabilities. We help you design electronic payloads with comprehensive functionality in mind, ensuring that they can perform reliably across diverse operating conditions. We focus on component selection, circuit board layout, and a robust supply chain supporting extended drone lifecycles. This collaborative approach has successfully miniaturized numerous drone electronic systems, including C2/C3 and ISR modules, supporting extended drone travel times and distances.
Benchmark's collaboration with drone developers spans product realization, from design to production stages, enabling us to swiftly scale production volumes as needed without compromising quality. This approach is effective for smaller drones and is scalable to support sub-systems and payloads for larger UAVs as required. Increasingly, smaller drones are equipped with radar and antennas for guidance and surveillance, or ISR capabilities, particularly in law enforcement applications. They may also feature communication circuits for many RF/microwave frequencies, even for short-range use at unlicensed millimeter wave frequency bands from 30 to 110 GHz. By combining our expertise in RF/microwave and diverse electronic technologies with comprehensive capabilities in developing tests for complex electronic functions, our engineers have supported compact drone payload packages with complete C2/C3 functionality. Designing, manufacturing, and testing high-speed, high-frequency circuits that fit the most miniature A&D drones helps ensure and enhance data interoperability. In addition to digital and RF/microwave technologies, these circuits incorporate electro-optical (EO) and infrared (IR) technologies.
Fitting Solutions
Developing smaller drones with enhanced A&D capabilities necessitates extremely dense, power-efficient circuits with subsystems that can fit within the limited payload space. These circuits must also be lightweight to avoid compromising the drone's flight time. They may incorporate cameras and thermal sensors for real-time data collection, with onboard artificial intelligence (AI) to aid in decision-making during critical situations. However, payload volume is limited, especially for hand-launched drones. Meeting these objectives requires multi-function circuits capable of uninterrupted operation across diverse conditions, such as rainfall, humidity, and fluctuating temperatures.
The significance of smaller drones is increasing in contested airspaces, requiring highly functional yet extremely compact electronic circuits and systems to fit their smaller frames. Success in A&D missions with smaller drones hinges on meeting reduced SWaP requirements. Fortunately, Benchmark has a proven track record in designing, manufacturing, and testing smaller, denser circuits, and providing aftermarket service in parts and repair.
Contact Benchmark to ensure that today's defense drones will be ready for tomorrow's battlespaces.
