Inside the Russian effort to build 6,000 attack drones with Iran’s help

Washington Post-Aug 17th2023

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The engineers at a once-bustling industrial hub deep inside Russia were busy planning. The team had been secretly tasked with building a production line that would operate around-the-clock churning out self-detonating drones, weapons that President Vladimir Putin’s forces could use to bombard Ukrainian cities.

A retired official of Russia’s Federal Security Service was put in charge of security for the program. The passports of highly skilled employees were seized so they could not leave the country. In correspondence and other documents, engineers used coded language: Drones were “boats,” their explosives were “bumpers,” and Iran — the country covertly providing technical assistance — was “Ireland” or “Belarus.”

This was Russia’s billion-dollar weapons deal with Iran coming to life in November, 500 miles east of Moscow in the Tatarstan region. Its aim is to domestically build 6,000 drones by summer 2025 — enough to reverse the Russian army’s chronic shortages of unmanned aerial vehicles, or UAVs, on the front line. If it succeeds, the sprawling new drone factory could help Russia preserve its dwindling supply of precision munitions, thwart Ukraine’s effort to retake occupied territory and dramatically advance Moscow’s position in the drone arms race that is remaking modern warfare.

Although Western officials have revealed the existence of the facility and Moscow’s partnership with Tehran, documents leaked from the program and obtained by The Washington Post provide new information about the effort by two self-proclaimed enemies of the United States — under some of the world’s heaviest sanctions — to expand the Kremlin’s drone program. Altogether, the documents indicate that, despite delays and a production process that is deeply reliant on foreign-produced electronic components, Moscow has made steady progress toward its goal of manufacturing a variant of the Iranian Shahed-136, an attack drone capable of traveling more than 1,000 miles.

The documents show that the facility’s engineers are trying to improve on Iran’s dated manufacturing techniques, using Russian industrial expertise to produce the drones on a larger scale than Tehran has achieved and with greater quality control. The engineers also are exploring improvements to the drone itself, including making it capable of swarm attacks in which the UAVs autonomously coordinate a strike on a target.

Researchers at the Washington-based Institute for Science and International Security, who reviewed the documents pertaining to the production process at the request of The Post, estimated that work at the facility in the Republic of Tatarstan’s Alabuga Special Economic Zone is at least a month behind schedule. The facility has reassembled drones provided by Iran but has itself manufactured only drone bodies, and probably for not more than 300 of the UAVs, the researchers concluded. Alabuga is unlikely to meet its target date for the 6,000 drones, they said.