Continuous Composites (CCI) has received a Phase II Small Business Innovation Research (SBIR) contract from the US Navy to advance its Continuous Fiber 3D Printing (CF3D) technology for uncrewed aerial vehicle (UAV) applications.
The project seeks to fabricate UAV structures that combine mechanical strength with integrated electrical functions, the company announced.
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The latest phase of the programme aims to embed electrical conductors directly within the composite materials of UAV components, replacing traditional wire harnesses and simplifying internal architectures.
CCI stated that this integration could lead to modular UAV designs, with quicker field repairs and lower risk of damage to internal wiring during maintenance.
During the initial phase of the programme, the company demonstrated the capability to co-print copper wiring and fibre optics within fibreglass-reinforced panels.
Mechanical and electrical tests conducted on these prototypes indicated that the introduction of conductive materials resulted in minimal impact on the structures’ load-bearing properties, supporting the viability of embedding functional elements into aerospace-grade composites.
The newly awarded Phase II contract covers a 30-month research and development period focused on scaling up the integration of high-capacity conductive pathways into larger, load-bearing structures.
According to CCI, the goal is to maintain mechanical performance and proper electrical isolation while increasing the level of functionality integrated into structural components.
Following this period, a one-year option will focus on demonstrating the technology in a functioning UAV system.
The initiative aligns with Department of War efforts to streamline system design, enhance maintainability, and increase the adoption of composite-based platforms.
Continuous Composites CEO Steve Starner said: “This programme represents a shift from printing structure alone to printing functionality directly into the structure.
“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.”
