Idaho-based Continuous Composites (CCI) has secured a Phase II Small Business Innovation Research (SBIR) contract from the U.S. Navy to advance its CF3D continuous fiber 3D printing technology for multifunctional UAV structures. The program aims to embed electrical conductors directly into load-bearing composite components, reducing the need for conventional wire harnesses.
During Phase I, CCI demonstrated the co-printing of copper wiring and fiber optics within fiberglass-reinforced composite panels. Mechanical and electrical testing showed minimal impact on structural integrity, supporting the feasibility of integrating functional materials directly into composite laminates.
The Phase II program will develop higher-capacity conductive pathways within structural components while maintaining mechanical performance and electrical isolation. The resulting components could simultaneously carry structural loads and electrical power, creating more integrated and modular UAV architectures.
The program includes a 30-month R&D period covering materials development, process validation, and embedded-conductor integration at coupon and sub-scale structure levels. A further one-year option period will support a functional system-level demonstration aimed at moving the technology toward operational UAV applications.
By integrating electrical functionality during composite manufacturing, the technology could also simplify UAV architecture, reduce wiring-related damage risks, and make damaged components easier to replace in field environments.
Source: Continous Composites | News
