General Dynamics’ factory in Mesquite, Texas. Photo: Desiree Rios for ProPublica.
This story was originally published by ProPublica.
A robot was on fire. Again.
It was the summer of 2024, and the cutting-edge robots inside General Dynamics’ sweltering artillery factory near Dallas were catching fire with startling regularity, according to four former workers there. This wasn’t ideal, as the plant was supposed to be churning out urgently needed artillery shells for Ukraine. The robots, giant metal arms with clamps for hands, would end up drenched in oil, which would then — no surprise — combust as they moved steel blocks heated to 1,800 degrees into and out of a machine that periodically erupted columns of fire. One blaze that summer melted a robot’s cables, putting it out of commission for a week.
Only weeks earlier, defense officials and executives had touted the factory’s innovative new machinery, imported from Turkey, at a gala opening ceremony. But employees were already used to spectacular mishaps, fiery and otherwise. “After the second, third, fourth time, it just became almost normal,” one former worker said. “It got to the point where I was not surprised by anything that happened there.”
Instead of producing shells in an efficient and streamlined fashion, the pricey machines kept failing in bizarre ways. The robot arms would swing out of control, smashing into carefully calibrated equipment, and sometimes they would unexpectedly drop hunks of steel 5 feet down to the floor. The factory’s signature device, meant to precisely stretch the steel for the artillery shells, instead often cracked it beyond repair.
Then there were the giant press machines, which required regular pounding with a sledgehammer to function properly but still botched the shaping of nearly every shell.
“We really didn’t have any standardized practice,” said Quantel White, a former employee. “It was just a bunch of guys taking turns going at the machine with a sledgehammer every night.” To workers, even the factory buildings themselves came to feel doomed, with acrid smoke hanging in 100-degree heat over foundations seemingly sinking into the earth.
A press machine at the General Dynamics artillery factory near Dallas, Texas. Video: Obtained by ProPublica.
The situation never improved. The U.S. Army, which funded the factory, ordered work halted on two of its three production lines in August 2025. By then, General Dynamics had blown eight deadlines. Work on the third production line continued, but the facility never produced a single usable shell, according to a report from the Department of Defense’s inspector general in July.
The fiasco has cost American taxpayers $533 million, according to the Army. But the Army has not held General Dynamics or a key Turkish subcontractor — which provided the factory’s much-hyped but little-proven equipment — publicly accountable for the failures. Nor has it made General Dynamics pay a penny back.
Just the opposite: General Dynamics, one of the world’s largest defense companies, has been showered with new contracts, continuing its track record as one of the greatest beneficiaries of Pentagon spending. The company is still in charge of the factory. It recently announced that it will fix things there by bringing in another much-hyped but little-proven technology.
“It’s an absolute disaster,” said one former official in an Army office supervising the project. “The Army should’ve gone after recovering money from General Dynamics,” added the official, who, like others interviewed for this story, spoke on the condition of anonymity.
Publicly, the Army has been tight-lipped about what, exactly, went wrong at the factory, located in a sprawling suburb called Mesquite. The inspector general report described the failure but offered few specifics. It didn’t name the companies involved, much less any of the individuals responsible. The report’s recommendations were tepid: The Army should determine whether the contract was “appropriately issued,” how “the money was spent” and whether it can recoup any of it. It should also “identify and implement a solution” for producing more artillery. Army officials deflected blame, telling the inspector general that they didn’t do anything wrong.
In a detailed statement to ProPublica, the Army said it will recover funding for the project by getting unspecified discounts from General Dynamics on production orders. “The Army is exercising rigorous oversight to ensure every dollar invested delivers capability to the warfighter,” the statement read. “Where vendors fail to meet contract specifications, as seen at the Mesquite facility, we are evaluating contract performance, seeking recoupment of funds, and pivoting resources.”
As for General Dynamics, it has given no public explanation whatsoever. The company has said that it “met or exceeded requirements,” according to the inspector general report. General Dynamics declined an interview request from ProPublica. Company spokesperson Jeff Davis said ProPublica’s reporting “fundamentally mischaracterizes the circumstances and falsely impugns our record of employee safety and truthfulness with our customer.” He continued: “An article based on this foundation would be a materially false and misleading hit piece.” Davis did not respond to ProPublica’s request that he specify the alleged errors.
