#United States #Coeur d'Alene #Continuous Composites #CF3D Technology #UAV Structures

Continuous Composites' New Phase II Contract with the U.S. Navy

Continuous Composites, known for its innovations in advanced composite manufacturing, has recently announced that it has secured a Phase II contract from the United States Navy. This contract is part of the Small Business Innovation Research (SBIR) program and aims to further develop the Continuous Fiber 3D Printing (CF3D®) technology specifically for multifunctional structures in Unmanned Aerial Vehicles (UAVs).

The Importance of CF3D Technology

The core of this project is the integration of electrical conductors directly into composite UAV structures. This breakthrough allows these composite materials not only to provide substantial load-bearing capabilities but also to function as integrated power distribution systems. As a result, the traditional reliance on wire harnesses is diminished, which simplifies the overall architecture of these advanced UAV platforms.

During the initial Phase I segment, Continuous Composites demonstrated an ability to co-print conductive elements within fiberglass-reinforced composite panels, including essential components like copper wiring and fiber optics. Rigorous mechanical and electrical testing revealed that these integrations did not compromise the mechanical strength of the panels, validating the potential for this innovative approach to composite manufacturing.

Advancements in Phase II

Moving into Phase II, Continuous Composites plans to enhance these functionalities further by incorporating higher-capacity conductive pathways within load-bearing components. This includes maintaining both mechanical performance and electrical isolation through strategic material placement. The goal is to ensure that the composite structures can bear loads while providing power without sacrificing integrity or performance.

This development is particularly important for field operations. The aim is to develop modular UAV architectures that permit rapid replacement of damaged components, while minimizing the risk of damaging wiring. This will lead to decreased maintenance complexity, reduced downtime, and increased reliability overall.

Steve Starner, the CEO of Continuous Composites, articulated the significance of this project, highlighting that it represents a paradigm shift from merely printing structures to embedding functionality directly into the structures. He explained that the introduction of electrical pathways into the structural components of UAVs creates opportunities for a new class of multifunctional systems designed to meet real-world operational requirements.

The Path Forward

The Phase II program is set to unfold over a 30-month research and development period. This phase will focus on validating materials and processes as well as integrating embedded conductors at both the coupon and sub-scale structure levels. Following this, a one-year option period will be available to demonstrate a functional, system-level model aimed at preparing the technology for operational deployment in UAVs.

This initiative not only supports Continuous Composites' innovative trajectory but also aligns with broader Department of Defense objectives aimed at reducing system complexity, enhancing maintainability, and accelerating deployment of advanced composite-enabled platforms.

About Continuous Composites

Founded with the vision of transforming composite manufacturing, Continuous Composites is at the forefront of advanced materials technology. Their patented CF3D® technology harnesses fiber steering, innovative materials, and automated production processes to create high-performance structures designed for critical applications in aerospace, defense, and UAV industries.