Continuous Composites Wins US Navy Phase II for 3D Printed UAV Structures

The US Navy is doubling down on a bold approach to drone manufacturing: printing the electronics into the airframe itself. Continuous Composites (CCI) has secured a Phase II Small Business Innovation Research contract to advance its Continuous Fiber 3D Printing (CF3D) technology for multifunctional unmanned aerial vehicle structures.

The program targets a specific problem in UAV design. Right now, wire harnesses snake through composite airframes, adding weight and creating failure points. CCI wants to replace those with conductive paths printed directly into the structure during the layup process. Load-bearing parts would also carry power.

What Phase I Proved

In the initial phase, CCI co-printed copper wiring and fiber optics inside fiberglass-reinforced composite panels. Mechanical and electrical testing showed minimal impact on structural integrity. That result matters a lot. If embedding wires weakened the part, the whole concept collapses. Instead, the data suggested functional materials can live inside composite laminates without compromising strength.

Phase II runs for 30 months, with a one-year option for a system-level flightworthy demonstration. The work will focus on higher-capacity conductive pathways, better electrical isolation, and scaling from small test coupons to sub-scale structures. The goal is a composite component that carries load and power without requiring separate harnesses or connectors.

Why the Navy Cares

For military drones, maintainability is everything. Field repairs on a damaged wing or fuselage section currently risk cutting wires or breaking connectors during part replacement. Embedded conductors change that equation. A technician swaps a printed composite patch without worrying about disconnecting avionics harnesses.

Steve Starner, CEO of Continuous Composites, put it plainly: "By embedding electrical pathways into load-bearing composite components, we are enabling a new class of multifunctional UAV systems designed for real-world operational environments."

The contract fits a broader Department of Defense push to simplify platform architecture, reduce logistical tails, and speed up field repairs. If CF3D graduates from sub-scale tests to operational hardware, it could reshape how the military thinks about airframe manufacturing. Conventional tooling and assembly lines give way to digital toolpaths and material deposition. That transition has been happening slowly across the industry. This program accelerates it for a specific, high-value use case.

The Bigger Picture

Continuous Composites is not the only company printing conductors into composites, but landing a Navy Phase II puts it ahead of many competitors for defense contracts. The 30-month timeline means results will emerge around 2029, assuming the option period gets exercised. Watch for sub-scale demonstrator results first. Those will signal whether the technology is ready for prime time or needs another research cycle.