Navy Awards Phase II Contract for 3D-Printed Drones With Built-In Electronics

The US Navy awarded Continuous Composites a Phase II Small Business Innovation Research contract to develop 3D-printed UAV structures with embedded electrical conductors. The goal is to replace traditional wire harnesses with conductive pathways printed directly into the composite skin.

During Phase I, Continuous Composites demonstrated copper wiring and fiber optics co-printed inside fiberglass-reinforced panels. Mechanical and electrical tests showed the conductive materials had minimal impact on load-bearing strength. That result matters because embedding functionality into structural parts usually weakens one or the other.

Phase II covers a 30-month development window focused on scaling those conductive pathways into larger, load-bearing structures. The team must keep mechanical performance and electrical isolation intact while adding more functionality. A one-year option follows to prove the approach in a working UAV system.

CEO Steve Starner described the shift as moving from printing structure alone to printing functionality directly into the structure. If the technology delivers, future drones could carry simpler internal architectures, faster field repairs, and less wiring damage during maintenance.

The contract aligns with broader Department of Defense efforts to adopt composite-based platforms that are easier to maintain and quicker to modify. Continuous Composites is one of relatively few companies printing continuous fiber composites with embedded conductors at scale.