HII Unveils Expanded ROMULUS USV Assembly Facility and Launches HYPR Robotics Initiative
HII has released a video outlining plans for a new ROMULUS unmanned surface vessel (USV) assembly facility at Breaux Brothers Enterprises in New Iberia, Louisiana. The company also introduced High-Yield Production Robotics (HYPR), an initiative focused on applying industrial robotics and digital quality systems to unmanned platform manufacturing.
Together, the facility and HYPR reflect HII’s vision for transforming how unmanned surface vessels are built. The company aims to move from prototype construction to scalable, repeatable production using automation, digital design, and standardized manufacturing processes. The approach is intended to lower unit costs, shorten production timelines, and support program-level delivery of the ROMULUS family of USVs.
Enhanced USV Assembly Facility
The upgraded Breaux Brothers facility is designed to support serial production of ROMULUS vessels ranging from approximately 20 feet to 190 feet in length. The expanded layout emphasizes automation, advanced tooling, and standardized workflows to enable efficient, high-rate production across multiple vessel variants using a common manufacturing approach.
The concept supports HII’s broader goal of creating a fully automated structural assembly environment tailored to the ROMULUS family. The initiative is intended to improve technical feasibility, schedule performance, and manufacturing efficiency, while positioning the company to scale production quickly as demand for autonomous maritime systems grows.
“ROMULUS is engineered from the outset for scale,” said Andy Green, president of HII’s Mission Technologies division. “By pairing a purpose-built assembly line with automation and strong industry partnerships, we are driving predictable production outcomes and lowering the cost of unmanned surface vessels. This positions us to deliver capability faster and at volumes aligned with fleet needs.”
High-Yield Production Robotics (HYPR)
HII’s HYPR initiative will integrate robotic welding, automated material handling, and digitally enabled quality assurance into an assembly-line environment optimized for ROMULUS production. In 2026, the company plans to conduct proof-of-concept demonstrations with multiple partners, with the goal of launching a full-scale pilot program in early 2027.
ROMULUS has been identified as a primary use case for HYPR, including the development of a fully automated structural assembly line for larger vessel variants. The approach is designed to enable concurrent hull construction, reduce labor hours and rework, and increase throughput while maintaining consistent quality across vessel classes.
“HYPR applies next-generation industrial robotics to shipbuilding processes that have traditionally been labor-intensive and difficult to automate,” said Eric Chewning, executive vice president of maritime systems and corporate strategy at HII. “For ROMULUS, this means fewer labor hours per hull, greater schedule predictability, and a manufacturing model that can scale efficiently as volumes increase.”
HII is working with partners including Breaux Brothers Enterprises and Incat Crowther to align vessel design, production tooling, and facility layout. The goal is to ensure ROMULUS vessels can be produced efficiently using commercial best practices adapted for autonomous naval platforms.
ROMULUS: Built for Scale and Mission Flexibility
ROMULUS USVs are designed to meet current and emerging requirements for the U.S. Navy, U.S. Marine Corps, joint forces, and allied customers. The modular family supports a wide range of missions, including intelligence collection, mine countermeasures, strike operations, and unmanned system deployment. A single platform can be configured for multiple roles through modular payload integration.
The vessels are built around HII’s Odyssey Autonomous Control System, which enables sustained open-ocean operations, coordinated multi-vessel operations, and integration of modular payloads. ROMULUS platforms also incorporate technologies from Shield AI, Applied Intuition, and C3 AI to enhance autonomous performance and lifecycle sustainment.
A ROMULUS prototype is currently under construction at the Breaux Brothers facility in Louisiana. Designed for rapid, repeatable production, the USV family emphasizes endurance, global reach, and adaptability as operational requirements evolve.
A Scalable Production Model for Unmanned Systems
By combining automated manufacturing, digital shipbuilding practices, and an assembly-line production model, HII is reshaping how unmanned surface vessels are produced. The planned ROMULUS facility marks a step toward industrial-scale production, enabling consistent and efficient delivery across a range of vessel sizes and mission configurations.
With ROMULUS, HII is applying automation and manufacturing discipline to unmanned maritime systems at scale, supporting the transition from experimental platforms to operational fleet deployment.
