Port Alpha: The US Navy's Astonishing Next-Gen Shipyard


Port Alpha: The US Navy's Astonishing Next-Gen Shipyard - YouTube

US Navy Backs Saronic's Port Alpha: Revolutionary Shipyard to Transform Unmanned Fleet Capabilities

By Military Affairs Correspondent
May 19, 2025

In a significant advancement for the US Navy's strategic vision of a hybrid fleet, defense technology company Saronic has secured $600 million in funding to establish Port Alpha, a revolutionary shipyard designed exclusively for constructing unmanned surface vessels (USVs). This development comes as the Navy accelerates its plans to integrate unmanned capabilities within its battle force, aiming for approximately 150 large unmanned platforms by 2045.

"We will bring these elements together with a single goal: to rapidly build a fleet of autonomous vessels in America that redefine maritime superiority and guarantees freedom of the seas for generations to come," said Dino Mavrookas, Saronic's CEO and co-founder, announcing the ambitious project in February.

Strategic Shift in Naval Warfare

Port Alpha represents a paradigm shift in American shipbuilding philosophy. Unlike traditional shipyards constrained by century-old practices, the facility will be designed from the ground up with modern manufacturing processes aimed at mass-producing autonomous vessels.

The Navy's interest in Port Alpha aligns with its Navigation Plan (NAVPLAN) that envisions a hybrid fleet consisting of more than 350 manned ships supported by approximately 150 large unmanned surface and subsurface platforms by 2045. This transformation is deemed essential to counter growing maritime challenges, particularly in the Indo-Pacific region.

Admiral Lisa Franchetti, recently ousted as Chief of Naval Operations, had been a vocal proponent of this hybrid approach. "The future idea with large unmanned is that that be a missile carrier," former CNO Admiral Mike Gilday stated previously, highlighting the strategic role envisioned for these vessels.


Production Capacity Breakthrough

Port Alpha promises to deliver production capabilities unseen since World War II. While Saronic has not yet selected a specific location for the facility, company executives have indicated that Texas and other Gulf Coast locations are under consideration, with construction anticipated to begin within the next five years.

The facility will build upon Saronic's existing capabilities in producing smaller USVs like the 6-foot Spyglass, 14-foot Cutlass, and 24-foot Corsair. However, Port Alpha will enable the production of medium and large autonomous vessels, potentially addressing the Navy's requirements for Medium Unmanned Surface Vessels (MUSVs) and Large Unmanned Surface Vessels (LUSVs).

According to current projections, the Navy plans to acquire two LUSVs per year starting in 2027, which would result in a force of 31 LUSVs by 2045 and a total of 40 by 2050. The Congressional Budget Office's analysis of the Navy's 2025 shipbuilding plan indicates this steady acquisition rate over nearly three decades.

Small USV Production Already Ramping Up

While Port Alpha represents the future of larger autonomous vessels, the Navy's immediate focus on smaller USVs is already showing results. The Global Autonomous Reconnaissance Craft (GARC), a 16-foot autonomous USV built by Baltimore-based Maritime Applied Physics Corporation, is being produced at an increasing rate.

"The sea service plans to ramp up GARC production to reach a goal of up to 32 units per month in 2025," according to DefenseScoop, highlighting the Navy's commitment to smaller autonomous platforms. With each GARC costing less than $1 million, these vessels represent an economical approach to expanding the fleet's capabilities.

The Navy recently announced plans to establish Unmanned Surface Vessel Squadron 7 (USVRON 7) in San Diego by mid-2025, which will join existing squadrons in operationalizing these autonomous systems.

Challenges and Questions Remain

Despite the promising developments, significant questions remain about the implementation of unmanned vessels in naval operations. The Navy is still developing conventions, policies, and procedures for managing these autonomous platforms, particularly regarding potential hostile interactions at sea.

William Daly, director of surface warfare, has expressed skepticism about the Navy's need for large autonomous ships, preferring medium-sized vessels that can be more easily produced. Additionally, the Navy's 2025 shipbuilding plan acknowledges that even with current funding levels—the highest since the 1980s—affording all planned ships remains challenging.

Technical hurdles also persist. The Navy recently completed extended reliability demonstrations of four different engine configurations for its LUSV program, testing their capability to operate for 720 continuous hours without human intervention—a critical requirement for autonomous operations.

Industry Transformation

Port Alpha represents more than just a new shipyard; it signifies a transformation of the American shipbuilding industry. With Saronic valued at $4 billion following its latest funding round, the company joins other defense technology firms like Anduril in leading a private-sector revolution in military production capabilities.

"The last years have seen a degradation in the capacity for the United States to build ships and to manufacture core needs of the country," noted Elad Gil, who led Saronic's funding round. "I am excited to back Saronic and its focus on revitalizing shipbuilding in America, while also building products to defend those interests."

As the Navy continues to refine its requirements and concepts of operations for unmanned vessels, Saronic's Port Alpha stands ready to deliver the next generation of autonomous maritime platforms, potentially reshaping naval warfare for decades to come.

Required Budget

Based on comprehensive research, I can provide an analysis of the budget required to achieve the US Navy's unmanned surface vessel plans and Port Alpha's role in this transformation.

Total Budget Requirements

The US Navy's ambitious plan to build a hybrid fleet with approximately 150 large unmanned platforms by 2045 represents a significant financial commitment across multiple funding streams:

  1. Overall Naval Shipbuilding Budget: According to the Congressional Budget Office (CBO) analysis of the Navy's 2025 shipbuilding plan, the total shipbuilding costs would average about $40 billion per year (in 2024 dollars) over the next 30 years. This represents a 46% increase over the average amount appropriated in the past 5 years and would require the Navy's total budget to increase from $255 billion today to $340 billion by 2054 to implement the plan.

  2. Unmanned Systems Budget: The Navy had previously planned to spend approximately $12 billion for unmanned platforms (aircraft, surface vessels, and underwater systems) between fiscal years 2021-2025, with about $2.2 billion allocated specifically for unmanned surface vessels and $1.9 billion for unmanned underwater vessels during that period.

  3. Private Investment in Production Capacity: Saronic Technologies plans to invest "billions of dollars" into Port Alpha, beginning with their initial $600 million Series C funding round that valued the company at $4 billion. CEO Dino Mavrookas stated they're "going to invest billions of dollars into the defense industrial race and bring shipbuilding back to this country again in a way that we have not seen since World War II".

Port Alpha Project Costs

Saronic's Port Alpha represents a private-sector initiative that complements the Navy's unmanned vessel ambitions:

  1. Initial Investment: The $600 million Series C funding round is just the beginning of Saronic's financial commitment to Port Alpha. When asked about the total cost of the project, company executives mentioned they planned to funnel "billions and billions of dollars" toward the effort over its lifecycle.

  2. Shipyard Development Timeline: While specific construction costs haven't been disclosed, Saronic expects to have Port Alpha operational "well within five years," suggesting an accelerated capital expenditure compared to traditional shipyard development.

  3. Public-Private Partnership: Saronic plans to collaborate with federal and state governments to maximize the impact of its investment, potentially leveraging public funds to enhance the project's scope and capabilities.

Navy Procurement Plans and Costs

For the unmanned vessels themselves:

  1. Large Unmanned Surface Vessels (LUSVs): According to the CBO report, the Navy's FY2025 budget plans to procure the first LUSV in FY2027 at an estimated cost of $497.6 million, with subsequent vessels costing approximately $326-331 million each. The Navy plans to acquire two LUSVs per year, resulting in a force of 31 LUSVs by 2045.

  2. Medium Unmanned Surface Vessels (MUSVs): Previous contracts for MUSV prototypes were valued at $34.9 million for the first vessel, with options for eight additional vessels potentially bringing the total contract value to $281.4 million.

  3. Small USVs: The GARC vessels (16-foot autonomous USVs) are relatively low-cost at less than $1 million per vessel, making them an economical option for mass production.

  4. Total USV Fleet Cost: Achieving the Navy's goal of approximately 150 large unmanned platforms by 2045, plus hundreds of smaller USVs, would likely require tens of billions of dollars in procurement funding over two decades.

Economic Impact and Industrial Base Transformation

Port Alpha represents more than just production capacity for unmanned vessels; it aims to transform the U.S. naval industrial base:

  1. Workforce Development: Saronic plans to create thousands of jobs and establish training pipelines to develop the specialized workforce needed for autonomous vessel production.

  2. Manufacturing Innovation: The company plans to use "processes and best practices from commercial manufacturing to redefine how ships are built in the autonomy era," focusing on "eliminating inefficiencies, optimizing workflows, and creating a production system that maximizes quality, scalability, and speed".

  3. Public-Private Partnerships: Saronic intends to collaborate with federal and state governments to establish partnerships that accelerate growth and enhance the broader shipbuilding ecosystem.

In summary, the total budget required to achieve the US Navy's unmanned vessel ambitions, including Port Alpha's development, will likely exceed $50 billion over the next two decades when accounting for both public procurement funding and private investment in production capacity. The Navy's broader shipbuilding plan, which includes unmanned vessels as a key component, is projected to cost approximately $1 trillion over 30 years according to CBO analysis.

 

Sources:

  1. "Saronic Raises $600M Series C to Take on Autonomous Shipbuilding," PRNewswire, February 18, 2025, https://www.prnewswire.com/news-releases/saronic-raises-600m-series-c-to-take-on-autonomous-shipbuilding-302379441.html
  2. "American USV Builders Anticipate Mass Demand from U.S. Navy," Defense Security Monitor, February 27, 2025, https://dsm.forecastinternational.com/2025/02/27/american-usv-builders-anticipate-mass-demand-from-u-s-navy/
  3. "Startup Saronic to build 'Port Alpha,' next-gen shipyard focused on autonomous vessels," Breaking Defense, February 18, 2025, https://breakingdefense.com/2025/02/startup-saronic-to-build-port-alpha-next-gen-shipyard-focused-on-autonomous-vessels/
  4. "UPDATED: Navy's Force Design 2045 Plans for 373 Ship Fleet, 150 Unmanned Vessels," USNI News, July 26, 2022, https://news.usni.org/2022/07/26/navys-force-design-2045-plans-for-373-ship-fleet-150-unmanned-vessels
  5. "An Analysis of the Navy's 2025 Shipbuilding Plan," Congressional Budget Office, 2025, https://www.cbo.gov/publication/61155
  6. "U.S. Navy's new NAVPLAN Calls for 150 Unmanned Ships by 2045," Naval News, August 2, 2022, https://www.navalnews.com/naval-news/2022/08/u-s-navys-navplan-calls-for-150-unmanned-ships/
  7. "U.S. Navy completes final testing milestone for Unmanned Surface Vessel Program," U.S. Navy, 2024, https://www.navy.mil/Press-Office/News-Stories/Article/4011047/us-navy-completes-final-testing-milestone-for-unmanned-surface-vessel-program/
  8. "Saronic unveils plans for autonomous shipyard," Defense News, February 18, 2025, https://www.defensenews.com/naval/2025/02/18/saronic-unveils-plans-for-autonomous-shipyard/

 

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