From Setback to Standard: How Learning Fast Delivered VAPOR® CLE to the Army’s MRR Program

The Moment That Matters Isn't the Win-It's the Reset

In defense technology, the defining moment isn't when you win-it's how quickly you learn, improve and deliver after a failure.

When AV's VAPOR® unmanned aircraft system (UAS), an all-electric vertical takeoff and landing (VTOL) platform, was not selected in the initial tranche of the Army's Medium Range Reconnaissance (MRR) effort, the feedback was clear-and candid.

Our system wasn't ready.

It was more prototype than deployable solution. It did not yet meet requirements for compact packout. It wasn't fully operational on Kinesis, the open-standard one-to-many robotic command-and-control system AV is iterating for the Army. It didn't meet the Army's expectation for system maturity.

We had a choice: walk away-or rebuild with purpose.

Listening Hard: Turning Gaps into a Roadmap

We didn't interpret the Army's feedback as a rejection. We treated it as a roadmap.

The requirements weren't abstract-they were operational. The system needed to deploy faster, integrate seamlessly, carry more, fly longer, and perform in real-world conditions from day one.

The AV team re-architected the platform with a focus on usability and speed of tactical employment. We replaced tool-assembly with quick-connect rotor blades, landing gear, and tail assembly. We shrunk the tactical footprint nearly 50-percent, reducing a 28-cubic foot, 110-pound packout to seven cubic feet and 58 pounds for a full packout.

Engineers upgraded the power system from a legacy battery lasting 75 minutes to an upgraded Amprius SA08 battery pack, extending endurance to 120 minutes, unlocking the persistent loitering demanded by operators.

The team embedded NVIDIA's Jetson Orin processor, adding onboard compute to enhance VAPOR's performance, autonomy, and capacity for future AI capabilities, and fully integrated the platform with Tomahawk Grip's TA5 control hardware and Kinesis software.

It wasn't a patch. It was a full reset, executed in 10 months, to deliver the next-generation VAPOR® Compact Long Endurance (CLE).

Engineering for the Mission, Not the Demo

VAPOR CLE wasn't built to impress in a lab. It was built to perform in the field.

Payload integration became central to that mission.

We incorporated Trillium's HD-40LVV gimbal, for high-definition intelligence, surveillance, and reconnaissance. And HD-40LVV-LP for laser target designation. We integrated SPOTR-Edge ATR (Automatic Target Recognition) to allow operators to move faster from detection to decision. We added a communications relay for MANET mesh networks, allowing operators remote viewing, camera control, and vehicle control.

We brought in the CACI Pit Viper-Air electronic warfare payload, expanding the system's mission profile into contested environments and giving operators a tool to mitigate radio frequency and WIFI threats.

And we aligned with DEVCOM Armament's Center's CLIK (Common Lethality Interface Kit) standards, enabling lethality integration and ensuring the platform supports evolving Army strike requirements.

The Road Back: Proving, Not Promising

Re-entering the Army's evaluation process meant one thing: proof.

Our venue was second tranche of the Medium Range Reconnaissance, a program pathway designed for acquisition speed without lowering the standards for reliability, usability, and immediate operational value.

The Army gave us a flyoff opportunity.

Independent evaluators assessed the system's performance on more than 35 key system requirements: flight endurance, sensor and targeting quality, operational readiness, operation day/night and in GPS denied environments.

Targeting was an early test. In forward flight, hundreds of feet above ground, VAPOR put a 60-millimeter mortar within five inches of target center. A first proof point of many to come; and validation of our payload drop software.

Mission testing continued, defined by performance not potential.

Testers deployed the system in minutes and demonstrated adaptability and effectiveness for ISR, EW, and strike missions, in dynamic conditions. The flight test card was lengthy and rigorous. And the results vindicating; the Army selected VAPOR for production award on the second tranche of the MRR program. We showed that we had listened and learned.

What It Means Going Forward

Bottom line, AV learned from failure, redoubled our effort and investment, and performed. The VAPOR experience represents our values: Results, Ownership, Innovation, Dedication to Customers. These things matter, learning fast and delivering successfully matters. We're proud to provide VAPOR CLE to American soldiers.

ABOUT THE AUTHOR

Jason Wright is a senior product line manager at AV with over 20 years of defense aerospace experience. He is experienced in leading complex projects and driving operational execution. Leading from the front, with the VAPOR engineering team has been the focus for the last 18 months. He emphasizes continuous learning and professional development, with a background in structured project delivery, cross-functional coordination, and supporting mission-focused aerospace and defense initiatives.

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