The production of precision ball screws, a critical component in missile guidance systems, continues to challenge U.S. defense contractors amid increasing demand and lengthy manufacturing timelines. These specialized components, which convert rotary motion into precise linear motion, are essential in missile actuators but require extensive lead times due to complex production processes.
Ball screws used in missiles must meet stringent specifications, including resistance to heat and minimal friction, and are significantly more precise than those used in commercial applications like automotive power steering. The manufacturing process involves sourcing specialized heat-resistant steel, heat treating it to prevent warping, and applying protective coatings such as chrome plating. These steps collectively extend production timelines to more than a year, with individual ball screws often costing over $1,000.
Industry insiders say that missile production is constrained by the slowest supplier in the chain. Jeff Kaney, former owner of BGT Aerospace—a specialist supplier to Northrop Grumman—explained that delivery of ball screws can take up to two years due to the intricate nature of design, manufacturing, and certification. He noted that defense contractors routinely place orders years ahead of schedule to mitigate potential disruptions.
In response to increased demand, Velocity One, which acquired BGT Aerospace, is investing in new machinery and process improvements to accelerate output. However, challenges remain industry-wide. The U.S. Defense Logistics Agency confirmed that extensive manufacturing protocols and rigorous quality checks contribute to prolonged lead times.
This bottleneck is not exclusive to the United States. According to a 2025 report by the U.S.-China Economic and Security Review Commission, China has struggled to meet its goal of domestically producing 80% of its high-end ball screws, with imports from Europe and Japan still comprising roughly 90% of its supply. Chinese firms have sought equity stakes in foreign companies to bridge this gap.
The surge in missile orders is linked to recent government contracts. In January, Lockheed Martin agreed with the Trump administration to triple production of Patriot PAC-3 interceptors, necessitating a corresponding increase in ball screw procurement by suppliers like Moog and Umbragroup. Although Moog’s CEO Patrick Roche asserted readiness to meet demand, he signaled potential supply chain risks. Lockheed Martin stated it is taking urgent measures, investing over $8 billion to expand manufacturing capacity, modernize factories, and strengthen commercial partnerships.
Similarly, Raytheon announced a contract in August to raise annual output of Tomahawk cruise missiles from fewer than 90 to 1,000 units. Yet, suppliers warn of delays. Cory Tellbuescher, chief commercial officer at Velocity One, said new ball screw designs could require up to a year for production readiness. Raytheon’s parent company RTX declined to comment on these supply challenges.
Smaller firms and startups are particularly impacted. Jalest Motion, a missile actuator manufacturer founded in 2022, established an in-house ball screw subsidiary, Saginaw Precision, to address ongoing sourcing difficulties. Industry veterans cite a shrinking manufacturing base as a contributing factor—many smaller shops have closed or been absorbed by larger entities, reducing available capacity for specialized orders.
Saginaw, Michigan, remains a historic hub for ball screw production dating back to General Motors’ contributions during World War II. Companies like Umbragroup maintain a significant presence, but the dearth of skilled machinists and high retooling costs limit rapid expansion. Pat O’Brien, owner of Ecmor, a small ball screw manufacturer, said his shop has declined contracts due to workforce shortages, underscoring broader capacity constraints.
The confluence of technical complexity, long certification cycles, and limited production capacity makes precision ball screws a persistent bottleneck in missile manufacturing, even as defense spending and production targets rise sharply. Defense contractors and suppliers continue to prioritize investments aimed at alleviating these limitations, but challenges remain in meeting accelerated timelines critical to national security needs.