A new partnership has emerged between defense AI startup Gecko Robotics and shipbuilder BPMI, focused on accelerating the construction and maintenance of American vessels. This initiative comes at a crucial time, as China’s shipbuilding capabilities are significantly outpacing those of the United States.
The announcement regarding the partnership took place on a Tuesday in Pittsburgh during a meeting where President Donald Trump engaged with AI companies and researchers. BPMI serves as the prime contractor for the Navy’s nuclear propulsion program, overseeing engineering, procurement, and the technical management of naval nuclear components. This includes the development of the Columbia-class nuclear submarine, expected to achieve initial operational capability in 2030, as well as the upkeep and modernization of Ohio-class and Virginia-class nuclear attack submarines. The Virginia-class submarines are part of an ongoing adaptation process through the Block V program, which aims to incorporate more advanced missile technology.
Building nuclear submarines poses many challenges, primarily due to stringent requirements ensuring their ability to withstand extreme pressure and extended periods underwater. The construction of a submarine involves multiple contractors, each utilizing distinct record-keeping methods, which can complicate and delay the communication of critical documentation throughout the manufacturing process. A report from the Government Accountability Office (GAO) in April 2025 highlighted that the Block V program was only achieving 60 percent of its annual output goals.
Jake Loosararian, co-founder and CEO of Gecko Robotics, emphasized the complexity of nuclear submarine construction, which requires coordination among around 400,000 vendors who often deal with extensive paperwork. Gecko Robotics aims to streamline this process using artificial intelligence (AI).
Gecko Robotics also manufactures drones capable of conducting detailed inspections of material strength, crucial in assessing the structural integrity of submarines. The data collected from these inspections can be integrated into the company’s digital twinning software—creating accurate virtual models of equipment to identify potential issues. Loosararian claims this innovative approach could accelerate production by as much as 90 percent, though this figure has not been independently verified.
In addition to accelerating building processes, the technologies being developed by Gecko Robotics aim to mitigate the shortage of skilled labor in the shipbuilding sector. Loosararian posited the need to enhance the effectiveness of workers with advanced tools, reducing the necessity for extensive training years in challenging tasks such as welding.
The current maintenance procedures for naval vessels are hindering global operations, as noted by Rep. Ken Calvert (R-Calif.) during a May 2024 hearing addressing naval readiness. Maintenance challenges affect nearly every branch of military service, and their consequences could be more severe in the event of a conflict with China.
The U.S. Navy currently comprises 297 ships compared to China’s 400, with estimates suggesting that by 2030, China’s fleet could expand to 435 vessels while the U.S. aims for 381. Maintenance difficulties could further exacerbate the U.S. military’s operational capacity; for instance, in a July 2023 op-ed, Senator Roger Wicker (R-Miss.) acknowledged that 40 percent of U.S. attack submarines are unavailable for deployment due to ongoing maintenance.
The comparative shipbuilding capabilities further illustrate the disparity, with China holding 53 percent of global shipbuilding capacity versus less than 1 percent for the United States. Consequently, Chinese vessels typically require less maintenance and benefit from quicker repair processes due to the prevalence of shipyards.
To bridge the existing gap, the Navy is exploring the potential of robotic and autonomous vessels, while still requiring manned submarines and surface vessels. Gecko Robotics is actively collaborating with the Navy to expedite the maintenance of aircraft carriers and submarines. During the Defense One Tech Summit in June, co-founder Troy Demmer detailed Gecko’s approach to enhancing maintenance efficiency, which includes deploying technology to assess material health before ships enter dry dock and ensuring timely, targeted repairs.
Moreover, incorporating autonomous inspections and AI analysis into the production phase of new ships could significantly streamline operations. Demmer noted the importance of improving the production efficiency of forged and cast components upstream, as delays in this area result in substantial financial losses when parts must be discarded due to inefficiencies.
