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15. August 2025
Us Air Force Drone Crashes Into Mediterranean Sea As 13 Million Mq-9 Reaper Falls Victim To Sudden Engine Failure
The US Air Force has confirmed that a $13 million MQ-9 Reaper drone crashed into the Mediterranean Sea last winter after its propeller suddenly detached from the engine. The incident, which occurred on December 16, 2024, was investigated by the Air Force and revealed that the mechanical failure led to the loss of thrust and ultimately resulted in the drone’s plunge into the sea.
According to the investigation report published on July 30, the Reaper was flying from an undisclosed location in Europe towards a scheduled mission when it suddenly slowed down and began to fall. The drone’s engine data showed that parts were moving at two different speeds, indicating that the propeller had separated from the engine. This issue is only possible if the splined coupling assembly fails, which led to a “sudden and permanent decoupling of the propeller from the engine, resulting in an unrecoverable loss of thrust.”
The drone’s pilot, who was flying the Reaper as part of the 20th Attack Squadron based at Whiteman Air Force Base, Missouri, took control of the situation by executing multiple checklists to maintain control and restore thrust to the aircraft. However, despite efforts to recover the drone, it ultimately crashed into the Mediterranean Sea.
The investigation found that the cause of the mechanical failure was a failure of the “splined coupling assembly,” which led to excessive wear and tear on the ring inside the gearbox. This ring has been identified as a potential weak point in the Reaper’s design and has been noted to have a history of failures. The incident is not an isolated one, with MQ-9 accidents being relatively common.
From fiscal 2015 to 2021, the Air Force averaged 7.2 class A mishaps per year, which are defined as those that cost at least $2.5 million or resulted in damage to a military aircraft. Over the same period, nearly 4.6 drones were destroyed each year. This data highlights the ongoing issue of mechanical failures and their potential consequences on military operations.
In recent years, there have been several incidents involving MQ-9s being shot down by militia groups in the Middle East. Additionally, at least 12 more drones have suffered mechanical failures since October 2022. Despite these incidents, the Air Force continues to rely on drones as a key component of its military operations.
The service expects its MQ-9 fleet to shrink from around 230 to about 190 next year due to retirements and accidents. The shrinking fleet is part of the Air Force’s efforts to reduce costs and improve efficiency in its unmanned aircraft program. General Atomics, the manufacturer of the MQ-9 Reaper, has emphasized the importance of regular maintenance and inspections to prevent similar failures.
The company has also highlighted the need for continuous testing and evaluation of its products to ensure they meet the highest standards of performance and safety. The Air Force Safety Center has logged three Class A unmanned aircraft mishaps as of August 5, 2025, which is down from a recent peak of nine in 2023.
The incident highlights the complexities and challenges involved in operating unmanned aerial vehicles (UAVs) in combat environments. While drones offer significant advantages in terms of stealth and precision, they also require careful maintenance and management to ensure their safe operation. As the military continues to explore new technologies and strategies for its drone warfare program, it is essential that lessons are learned from incidents like this one.
The Air Force’s experience with MQ-9 accidents serves as a reminder of the importance of investing in research and development, as well as implementing effective safety protocols to prevent such failures. The ongoing efforts to improve drone safety and performance will be crucial in ensuring that these systems continue to play a vital role in modern military operations.
The incident is a sobering reminder of the risks involved in operating complex unmanned aircraft systems. The loss of the $13 million Reaper drone serves as a call to action for the military to prioritize maintenance, testing, and evaluation of its UAVs to ensure their safe operation and effectiveness on the battlefield.