Continuous Composites Wins Navy Contract to 3D Print Multifunctional UAV Structures

From structure to system

Continuous Composites just received a Phase II SBIR contract from the U.S. Navy to build UAV components that are both load-bearing and electrically active. The company already proved in Phase I that it can print conductive copper wiring and fiber optics inside fiberglass-reinforced composite panels without ruining the structural integrity. Now the program shifts from proving feasibility to engineering parts that can survive real flight loads.

Why embed the wiring

Traditional UAVs rely on separate wire harnesses for power distribution. Those harnesses add weight, create failure points, and make field repairs slower. Continuous Composites prints the conductors directly into the structure. Damaged sections can be swapped faster because there are fewer connectors to rip out. For drones operating far from depot-level maintenance, that resilience matters more than shaving a few grams off the airframe.

What comes next

The 30-month Phase II program will validate higher-capacity conductive pathways inside load-bearing parts. The team needs to keep the embedded copper electrically isolated while preserving the surrounding composite's mechanical performance. A one-year option period follows for a functional system-level demonstration. Continuous Composites already has a track record with similar contracts: an Air Force deal for anisotropic composite simulation and a multi-year Army program on missile components.

A pattern across services

The Navy award fits a broader Department of Defense push to simplify logistics and put function into printed structures rather than bolting it on afterward. If the company can reliably print power distribution into wing spars, fuselage ribs, or tail sections, it changes how military drones are designed and repaired.