American Dynamism Scorecard 2025: Tracking Progress in Aerospace, Defense & Manufacturing

Mar 21, 2025

Aerospace: U.S. remains a global leader with $73 billion space budget (2023) and milestones like Intuitive Machines' first commercial lunar landing. SpaceX continues to dominate with reusable rockets and over 5,000 Starlink satellites.
Defense: Hypersonic weapons development accelerates, with AI improving battlefield precision and counter-drone tech. The U.S. military is also enhancing cyber defenses with zero-trust architecture and advanced visualization tools.
Manufacturing: Automation and 3D printing are transforming production, increasing efficiency by 20–50%. Onshore production is projected to reach 44% capacity by 2028, addressing workforce gaps with training programs like Edmonds College's 92% aerospace job placement rate.

Key Challenges:

Supply Chain Stability: AI-driven tools and transparency needed to address shortages and delays.
Workforce Training: 2.4 million manufacturing jobs may go unfilled by 2030 without skill development.
Global Competition: U.S. must boost domestic production of critical materials and reduce reliance on imports.

Quick Comparison of Progress Metrics

Category Key Metric 2025 Status Aerospace Space budget $73 billion (2023) Defense Hypersonic weapons investment $8 billion since 2019 Manufacturing Onshore production 44% projected by 2028 Workforce Training Job placement rates 92% for Edmonds College graduates

American Dynamism Scorecard 2025: Tracking Progress in Aerospace, Defense & Manufacturing

To stay ahead, the U.S. must rebuild its industrial base, invest in advanced technologies, and strengthen workforce training. These efforts are crucial to maintaining leadership in these critical sectors.

Aerospace Progress Report

Space Industry Results

The U.S. space sector maintained its position as a global leader with a $73 billion budget in 2023, far exceeding other nations. SpaceX's Starlink network grew to over 5,000 satellites, further cementing the U.S.'s dominance in commercial space activities.

In February 2024, Intuitive Machines achieved a major milestone with the first commercial lunar landing under NASA's Commercial Lunar Payload Services (CLPS) program. Their Odysseus lander, launched aboard SpaceX's Falcon 9, successfully touched down in the Moon's south polar region, showcasing the growing capabilities of private-sector space ventures.

A notable shift occurred in 2023 when defense-related space spending surpassed civil space budgets for the first time. This was highlighted by the U.S. Space Force's Victus Nox mission, which deployed a satellite just 27 hours after receiving orders. This rapid deployment demonstrated the critical importance of quick-response capabilities for national security.

"Secure our Nation's interests in, from, and to space." – U.S. Space Force

These advancements in space technologies are influencing innovations in aircraft design.

Modern Aircraft Development

Aircraft manufacturers are using advanced composites to improve efficiency and performance:

Aircraft Model Composite Usage Performance Impact Boeing 787 Dreamliner 50% of structural weight 15–20% better fuel efficiency Airbus A350 XWB 53% of structure Improved aerodynamics and reduced drag F-35 Lightning II 35% advanced composites Enhanced stealth; radar cross-section < 0.1 m²

The Boeing 787, for example, uses carbon fiber-reinforced polymer (CFRP) to reduce weight by 20%, while the F-35 incorporates composites that enhance both stealth and efficiency.

Urban Air Transport Status

Urban air mobility is advancing thanks to cutting-edge manufacturing techniques and material innovations. Automated Fiber Placement (AFP) and Automated Tape Laying (ATL) technologies are improving production speed and consistency, enabling faster production cycles while supporting efficiency goals.

Artificial intelligence and machine learning are now integral to design and manufacturing processes, speeding up development timelines. This is particularly evident in the electric vertical takeoff and landing (eVTOL) sector, where lightweight composites play a crucial role in achieving better performance and range.

The industry is also experimenting with biocomposite materials made from natural fibers and bio-based resins. While these materials currently fall short of synthetic alternatives in terms of mechanical strength, ongoing research is steadily improving their potential for broader use.

Reaching New Heights: Navigating Aerospace and Defense ...

Defense Technology Update

The U.S. continues to push forward in defense technology, building on its aerospace achievements to maintain its edge in both technology and industry.

Military AI Systems

The U.S. military is integrating artificial intelligence to improve the efficiency and precision of its defense systems. For example, the United States Air Force is leveraging AI-enabled technologies for dynamic targeting, with the Shadow Operations Center at Nellis Air Force Base playing a key role. Lt. Col. Shawn Finney highlights the benefits:

"Modern battlefields are exceedingly complex and require the ability to distill an immense amount of information into a cohesive, actionable amount. The emergence of artificial intelligence in warfighting applications potentially gives battle managers the ability to focus on the most salient aspects of the operational area by reducing the volume of information they must evaluate."

AI is also revolutionizing counter-drone measures. High-energy lasers powered by AI have made it easier to identify and neutralize threats. Professor Brij Agrawal explains:

"Defending against one drone isn't a problem. But if there are multiple drones, then sending million-dollar interceptor missiles becomes a very expensive tradeoff because the drones are very cheap."

These advancements are laying the groundwork for faster progress in hypersonic weapons technology.

Hypersonic Weapons Status

The Department of Defense has ramped up its hypersonic weapons program, investing over $8 billion since 2019. Current efforts are concentrated on two main platforms:

Program Type Details Timeline Common Hypersonic Glide Body (C-HGB) A joint Army-Navy project with mobile ground and ship-launched capabilities Army deployment by FY2025 Air Force Hypersonic Cruise Missile Tested successfully in the Pacific on March 17, 2024 Still under development

These weapons, capable of traveling faster than Mach 5 (roughly 4,000 miles per hour), can strike targets thousands of kilometers away in just 15–30 minutes.

"This test is intended to send a clear message to Beijing, namely that Washington remains steadfast in reinforcing its strategic posture in the Pacific, even amidst competing global challenges."

Military Cyber Defense

The U.S. Army is strengthening its cyber defense capabilities with a zero trust architecture and improved network security. The Cyber Situation Understanding (Cyber SU) system offers critical visualization tools for cyber and electronic warfare scenarios.

Lt. Col. Scott Shaffer, product manager for Mission Command Cyber, explains its importance:

"Cyber SU serves as the digital, acetate overlay to provide CEMA awareness, mission impacts, risks and visualization within the Army command posts to assist tactical commanders with making more informed decisions in multi-domain operations."

Key components of the Army's cyber defense strategy include:

Component Function Status Zero Trust Architecture Continuous authentication and validation Being deployed Cyber SU Visualization and threat detection for tactical use Expanding to 10 additional units Cloud Computing Improved identity management and network resilience Currently implementing

"We're looking at a zero trust architecture that's going to enable us to operate in a tactical environment as well as an enterprise environment and pivot between the two."

Manufacturing Sector Analysis

The U.S. manufacturing sector is undergoing a transformation, driven by technology and automation, which continues to bolster the nation's industrial strength.

3D Printing Industry Growth

Industrial-grade 3D printing has shifted from being just a prototyping tool to a key production method. It now supports multi-material builds, reducing both assembly time and costs. With the integration of AI and machine learning, these systems can monitor processes in real-time, detect failures early, and establish localized production hubs to meet regional demands efficiently.

Manufacturing Metric Impact Production Speed 20–50% increase in output Quality Control 1.4% annual productivity improvement Labor Efficiency 3–5× workforce multiplication

Automated Factory Systems

Automation technologies, including robotics and IoT, are reshaping U.S. manufacturing by improving efficiency and flexibility. Currently, manufacturers contribute 11.5% to the nation's total output and employ 10% of the workforce. The rise of "new collar" workers with digital skills is also helping to address long-standing workforce gaps.

Some key benefits of automation include:

Benefit Category Improvement Range Cost Reduction 20–50% decrease Production Efficiency Up to 1.4% annual gain

New Materials Progress

Advancements in materials are pushing manufacturing capabilities further, especially when paired with automated systems. These developments are helping U.S. manufacturers achieve cost competitiveness with overseas production while maintaining higher quality standards. These innovations are setting the stage to tackle broader challenges, such as supply chain resilience and workforce development, which will be explored in future analyses.

Issues and Solutions

The aerospace, defense, and manufacturing industries face major hurdles that demand focused solutions to ensure the U.S. remains a leader in these sectors.

Supply Chain Stability

Supply chain disruptions are slowing production. Aerospace executives are now mentioning supply chain concerns 18 times more often in earnings calls compared to 2014. These disruptions impact several areas:

Impact Area Challenge Solution Component Availability Shortages of critical parts AI-driven early warning systems Production Timeline Delivery delays Improved transparency in subtier levels Quality Control Higher defect rates Root cause analysis training

By adopting a data-focused supply chain management strategy, companies can cut shortages by over 25%. Regular updates and better tracking tools are essential for smoother operations. These challenges also highlight the importance of strengthening workforce skills.

Worker Training Needs

The manufacturing industry is expected to create 4.6 million jobs over the next decade, but 2.4 million could go unfilled due to skill gaps.

Collaborations between industry and education are helping close these gaps. One standout example is Edmonds College's Advanced Manufacturing Skills Center (AMSC), which partners with industry leaders to train students:

"The best part about this module is that the students get to work on the exact same equipment and materials that they would work on if they go to work for Boeing...We hold our students to a very high standard at the school to ensure they are prepared when they graduate to a new career."
– Larry Cluphf, Executive Director of the AMSC

The program has achieved a 92% placement rate for graduates in aerospace roles. Bridging the skills gap is just as critical as addressing supply chain challenges.

Global Market Position

U.S. manufacturing is under pressure from global competition and rapid tech changes. Key issues include rising raw material costs affecting Department of Defense budgets, aging fleets reducing operational readiness, and quality control problems in commercial aerospace.

"Talent development is important in all industries, but its importance is especially heightened in an industry rich with technology and complex systems...When it comes to remaining competitive, I would argue the number one differentiator for a country, community or employer is access to talent."
– Jeannine Kunz

The Manufacturing USA network is addressing these challenges by collaborating with over 2,000 organizations on more than 500 major R&D projects. These efforts are crucial for maintaining the competitive edge outlined in the 2025 scorecard.

Conclusion: Next Steps

The 2025 scorecard highlights urgent priorities to maintain U.S. leadership in aerospace, defense, and manufacturing. Industrial decline is a pressing issue: U.S. steel production has plummeted 62% since its 1973 peak, while China now produces 12 times more steel.

Here are three areas that demand immediate attention:

Priority Area Current Challenge Required Action Industrial Base Aluminum production has dropped 81% since 1980 Introduce targeted tax credits and interest-free loans Supply Chain 80% of APIs depend on foreign sources Reduce reliance on overseas manufacturing Defense Innovation $1.8 billion projected DoD spending on 3D printing by 2032 Expand advanced manufacturing capabilities

These priorities highlight the need to strengthen both industrial production and defense technology. Neal Orringer, President of ASTRO America, emphasizes the collaborative effort required:

"Working together, we will build an innovative and resilient technology base. Not only will we train a new generation of advanced manufacturing engineers, and operators but we will ensure the Navy's access to critical capabilities for prototyping, producing, and validating key parts, components, and materials through advanced manufacturing and 3D printing capability."

A recent example of progress is IperionX's $47.1 million Department of Defense contract for titanium 3D printing powders. However, vulnerabilities remain, as the U.S. still relies entirely on imports for 12 critical minerals.

Elon Musk's perspective sheds light on the challenge of scaling manufacturing:

"The difficulty and value of manufacturing is underappreciated... It's relatively easy to make a prototype but extremely difficult to mass manufacture a vehicle reliably at scale. Even for rocket science, it's probably a factor of 10 harder to design a manufacturing system for a rocket than to design the rocket. For cars it's maybe 100 times harder to design the manufacturing system than the car itself."

To reclaim its position, the U.S. must rebuild domestic manufacturing, invest in workforce training, and use federal procurement to strengthen domestic capabilities and develop advanced technologies.