Congressional Report Questions Marine Corps ACV Plans Amid Ukraine Lessons

The Congressional Research Service released a report on Tuesday questioning the vulnerability of the Marine Corps' Amphibious Combat Vehicle to drone threats observed in Ukraine. The report asked how vulnerable ACVs are to threat systems during amphibious operations and when operating ashore. It also raised questions about whether the Marines are considering additional survivability modifications based on lessons learned in Ukraine, where armored vehicles have largely been driven from the battlefield by unmanned aerial vehicles and guided munitions. The ACV has already experienced teething pains.

Marines act on drone threat with new counter-UAS system

The Marine Corps awarded a contract last month to Anduril for a counter-UAS system to protect the ACV from small drones. Anduril’s Pulsar-L is a sensor and jammer package designed to stop small Group 1 and 2 radio-frequency drones. The system is currently in use by the Special Operations Command due to its low weight, proven performance in engaging multiple UASs, and ability to execute the full kill-chain while static or on the move.

Force structure growth may drive need for more ACVs

The Congressional Research Service questioned whether a possible plan to expand the Marine Corps would require more ACVs, which cost about $6 million each, depending on the variant. Last month, a Force Structure Review suggested adding more than 6,500 personnel by 2032, including additional slots in 19 infantry battalions and two Littoral Combat Teams. If the plan is implemented, the CRS asked whether additional ACVs would be required to accommodate growth in Marine infantry units.

Current ACV plan and variants under review

The Marines now plan for 608 ACVs across four variants, down from an initial 1,122. Marine Corps officials told CRS the current plan comprises the following:

BAE was just awarded a $230 million contract modification for 32 ACV-Rs, which will be the final ACV variant. The order is scheduled to be fulfilled by November 2028. For fiscal 2027, the Navy is requesting $237 million for ACV upgrades.

Weight and corrosion challenges prompt reduction efforts

One issue is the weight of the ACV, which now stands at around 35 tons. After two ACVs tipped over in 2022 while operating in surf up to 10 feet high, the Marines briefly suspended ACV operations in the open ocean, as long as significant breaker height doesn’t exceed four feet. In 2025, a Navy Small Business Innovation Research solicitation called for reducing the weight of all ACV variants, particularly the heavier ACV-30 and ACV-R. The goal is to slim down at least 2,000 pounds per vehicle.

Components identified as having potential for weight reduction include engine access covers, drive shafts, ramp door, ramp, hatches, external fuel tanks, external metallic and metallic/composite add-on-armor components, suspension, turret exterior panels, and bow plane. The weight reduction SBIR specified that any solution must address corrosion issues expected from use in and around salt water. Weight reduction will improve fuel efficiency and can lower the Center of Gravity and Center of Buoyancy.

Saltwater corrosion of ACV struts has created problems. A January 2026 Sources Sought notice for more than 5,000 corrosion-resistant struts claimed the high deployment schedule combined with the high training tempo of the United States Marine Corps creates an extremely corrosive environment for the ACV not typically experienced by other vehicles. The Marines are evaluating whether to modify ACVs for greater survivability based on lessons from Ukraine.