Future cost, use of Marine Corps ACVs scrutinized in congressional report

With today’s armored vehicles vulnerable to drones, congressional researchers are raising questions about the U.S. Marine Corps’ new Amphibious Combat Vehicle.

In particular, a Congressional Research Service report, released Tuesday, pointed to the war in Ukraine, where armored vehicles have largely been driven from the battlefield by unmanned aerial vehicles and guided munitions.

“As ACVs are intended to provide organic, direct fire support to dismounted Marines in the attack, how vulnerable to these threat systems are ACVs during amphibious operations and when operating ashore to support combat operations?” the research service asked in its report. “Are the Marines considering additional ACV survivability modifications based on lessons learned in Ukraine?”

In fact, the Marine Corps did award 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 the system’s low weight, proven performance in engaging multiple UASs, and simultaneous execution of the full kill-chain while static or on the move,” noted the Marine contract award.

The Congressional Research Service also questioned whether a possible plan to expand the Marine Corps would, in turn, 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, “would additional ACVs be required to accommodate growth in Marine infantry units?” CRS asked.

The ACV comes in multiple variants, including the ACV-P troop carrier, ACV-C command vehicle, ACV-30 fire support model armed with a 30mm cannon, and the ACV-R armored recovery vehicle.

Initially, the Marines envisioned buying 1,122 ACVs. But the current plan is for 608 vehicles, comprising 389 ACV-P, 33 ACV-C, 152 ACV-30 and 34 ACV-R, Marine Corps officials told CRS.

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.

The ACV has already experienced teething pains. 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.

One issue is the weight of the ACV, which now stands at around 35 tons. In 2025, a Navy Small Business Innovation Research solicitation called for reducing the weight of all ACV variants, and 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 2025 solicitation stated.

Saltwater corrosion of ACV struts has also created problems.

“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,” claimed a January 2026 Sources Sought notice for more than 5,000 corrosion-resistant struts.

In addition, 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.”