In a revealing interview with Ukrainska Pravda, a Ukrainian soldier known as “Petro” shed light on the real state of Russian drones used in combat. “At military exhibitions, Russian drones appear flawless, featuring pristine metal fittings and securely tightened aluminum screws. However, in reality, they’re mostly held together by cable ties and superglue,” Petro shared.
Petro explained that while the “cable ties and glue” might be seen as a crude mockery of Russian technology, it poses a significant challenge for Ukraine. Despite their simplistic construction, these drones remain operational and a nuisance for the Ukrainian army. Moreover, this cost-effective manufacturing approach allows Russia to produce these lethal drones inexpensively, posing a consistent threat.
Another critical concern for Ukrainian defense, according to Petro, lies in the advancement of Russian engineering—particularly in their communication systems. Although many drones still incorporate components imported from the West, recent months have seen an increase in locally produced communication systems. This shift means that while Western cameras and autopilot controls might still be used, the communication technology is predominantly Russian-made. As a result, Russian manufacturers are becoming increasingly self-reliant in this critical area.
BulgarianMilitary.com highlights the increasing prevalence of cost-effective solutions in Russia’s strategic playbook, noting their growing success. It began with the so-called “cope cages” for heavy combat vehicles. Initially dismissed as ineffective, these modifications are now seen on tanks in both the Russian and Ukrainian armies. Interestingly, Israel’s Merkava tanks have similar additions, mass-produced.
Furthermore, the initially ridiculed car tires on the fuselages of Tu-95 and Tu-160 bombers have a practical application. American intelligence reports suggest these tires act to confuse recognition systems in reconnaissance drones and attack missiles, which fail to identify the structure and graphics based on pre-loaded data of “enemy objects.”
However, while using cable ties and glue might cut production costs, it doesn’t guarantee the same level of performance and efficiency. Often, these quick fixes can compromise reliability and durability. Proper fittings and bolts are designed to securely attach components, which is crucial for systems operating under extreme loads and vibrations.
Using simpler solutions like glue and cable ties might seem cost-effective, but they can compromise both the stability and precision of drone operations over time. Particularly when exposed to high temperatures or mechanical stress, these makeshift fixes can cause significant issues.
While such methods can lower production costs and speed up assembly, they also raise serious concerns about the quality and durability of military equipment. Drones that aren’t securely assembled can be more prone to breakdowns and may suffer from reduced accuracy during critical missions.
Moreover, unreliable connections in key components can lead to system failures at crucial moments, which directly impact the effectiveness of military operations and the safety of the personnel relying on these drones.
In the U.S., it’s well understood that cutting corners on materials and time rarely yield good results, especially in the aerospace sector. Although the current issues with Russian drones in the conflict shouldn’t be directly compared to the Challenger disaster, it’s a stark reminder of how neglecting small details can lead to significant consequences.
As a reminder, the catastrophic Challenger explosion was caused by a flaw in the O-rings of the solid rocket boosters, which were supposed to create a secure seal between the rocket segments.
These O-rings, crafted from flexible rubber, failed to function properly in the cold temperatures on launch day. Despite engineers’ warnings about the potential dangers, the decision was made to stick with the flawed O-rings instead of opting for more reliable materials.
This critical failure led to a fuel leak and the subsequent explosion of the shuttle, tragically killing all seven astronauts on board. The Challenger disaster underscores the significant risks of cutting corners with materials or compromising the quality of vital systems.
In a parallel situation, criticisms are emerging in Russia about the Kremlin making “similar decisions.” Mikhail Lutsky, head of education programs at Geoscan in Russia, notes that sanctions have severely complicated the procurement of essential components like microchips. This has, in turn, forced the use of cheaper and less reliable materials, escalating costs, and undermining the quality of drones, which could jeopardize their combat effectiveness.
Samuel Bendett, an expert from the Center for Strategy and Technology Analysis, also voiced his concerns regarding the quality of Russian drones. He highlights that the lack of standardization in the producing process leads to serious issues, including up to 50% of Russian drones being downed by their own electronic warfare systems. Bendett also points out that poor-quality materials frequently cause malfunctions, with a third of the drones failing to even take off.
Source: Bulgarian Military.com