U.S. Navy funds Phase II for embedded-power UAV composites

Continuous Composites (CCI) received a Phase II Small Business Innovation Research contract from the U.S. Navy to continue development of its Continuous Fiber 3D Printing technology for multifunctional unmanned aerial vehicle structures.

The program is focused on embedding electrical conductors directly into composite structures so load-bearing parts can also distribute power. This can reduce or remove conventional wire harnesses and simplify UAV system architecture.

In Phase I, CCI co-printed conductive elements in fiberglass-reinforced composite panels, including copper wiring and fiber optics, and assessed structural and electrical effects through testing. The company reported limited effect on mechanical performance, indicating that functional materials can be integrated into composite laminates.

Phase II will continue work on integrating embedded conductors into composite architectures. The effort includes adding higher-capacity conductive paths in load-bearing parts while maintaining mechanical performance and electrical isolation through controlled material placement.

The approach is intended to support structurally integrated power systems for more modular UAV designs. In field maintenance, damaged parts may be replaced with lower risk of damaging wires and connectors, which can reduce repair effort and downtime.

The Phase II program includes a 30-month R&D period for materials development, process validation and embedded conductor integration at coupon and sub-scale structure levels. A one-year option period follows for a functional system-level demonstration to support transition toward operational UAV use.

The project aligns with broader Department of Defense goals to reduce system complexity, improve maintainability and accelerate deployment of advanced composite-based platforms.

For more information, visit continuouscomposites.com.

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