Continuous Composites awarded U.S. Navy Phase II contract to advance CF3D technology for embedded electrical systems in UAV structures

Continuous Composites (CCI), a leader in advanced composite manufacturing, has been awarded a Phase II Small Business Innovation Research (SBIR) contract with the U.S. Navy to further develop its Continuous Fiber 3D Printing (CF3D) technology for multifunctional Unmanned Aerial Vehicle (UAV) structures.

The programme focuses on embedding electrical conductors directly within composite structures, enabling load-bearing components that also serve as integrated power distribution systems. This approach eliminates the need for traditional wire harnesses and simplifies system architecture in UAV platforms.

During Phase I, CCI demonstrated the ability to co-print conductive elements within fiberglass-reinforced composite panels, including copper wiring and fibre optics, and evaluated their impact on structural performance through mechanical and electrical testing. Results showed minimal impact on mechanical integrity, validating the feasibility of integrating functional materials within composite laminates.

Building on these findings, Phase II will advance the structural integration of embedded conductors within composite architectures. The effort will focus on incorporating higher-capacity conductive pathways into load-bearing components while maintaining mechanical performance and electrical isolation through controlled material placement. Emphasis will be placed on ensuring that structural integrity is preserved as functionality is introduced, enabling composite components that carry both load and power without compromising performance.

The result is a structurally integrated power system that enables more modular UAV architectures. In field operations, damaged components can be rapidly replaced while reducing the risk of damaging wires and connectors, decreasing repair complexity, minimising downtime, and improving overall system reliability.

"This program represents a shift from printing structure alone to printing functionality directly into the structure," said Steve Starner, CEO of Continuous Composites. "By embedding electrical pathways into load-bearing composite components, we're enabling a new class of multifunctional UAV systems designed for real-world operational environments."

The Phase II programme includes a 30-month research and development period focused on materials, process validation, and embedded conductor integration at the coupon and sub-scale structure level. This effort is followed by a one-year option period to deliver a functional, system-level demonstration, advancing the technology toward deployment in operational UAV platforms.

This work supports broader Department of Defense initiatives to reduce system complexity, improve maintainability, and accelerate the deployment of advanced composite-enabled platforms.