Operational Dominance Through Resilient UAS: Passive Thermal and EMP Protection for Mission-Critical Drone Systems

Drone malfunctions in extreme climates are no longer theoretical—they are well-documented operational vulnerabilities that degrade ISR continuity, mission success, and tactical readiness. U.S. and allied forces have observed widespread Group 1–3 UAS failures due to sub-zero lithium battery degradation, desert heat-induced thermal runaway, and increasing threats from electromagnetic pulse (EMP) events. These vulnerabilities present unacceptable risks to autonomous operations in polar, desert, and contested environments.To address this urgent gap, PHOOZY, in partnership with Pennsylvania State University, developed a novel multi-function composite during Phase I that combines passive thermal insulation and embedded EMP shielding in a single, lightweight material. This zero-power solution protects drone batteries and electronics across –50°F to 300°F, reduces thermal and electromagnetic failure rates by over 80%, and extends mission duration and payload capacity by up to 60%. Unlike bulky enclosures or active thermal systems, the solution adds negligible SWaP and is compatible with additive manufacturing, enabling tailored integration into battery bays, payload housings, and avionics pods on Group 1–3 UAS platforms.This Phase II effort will transition the composite from lab validation (TRL 4) to operational integration (TRL 7). PHOOZY will refine designs based on Air Force end-user input, fabricate prototypes for at least two drone platforms, and validate survivability under cold, heat, and EMP stressors through bench and field testing. Testing and transition planning will be led by MSgt Richard Stone and Lt Col Nicholas Vogel of the 194th Wing, with additional support from AFRL/RX and Task Force 99. The effort supports Air Force priorities under Agile Combat Employment (ACE), contested logistics, and autonomous ISR in disconnected and denied environments.PHOOZY’s solution aligns with multiple OUSD(R&E) Critical Technology Areas, including Advanced Materials, Integrated Networked Systems-of-Systems, Trusted AI and Autonomy, and Renewable Energy Storage. With over 500,000 commercial units sold and $11M in non-defense revenue, PHOOZY has proven its thermal technology in logistics, emergency response, and industrial markets. However, this composite—enhanced for defense—is not commercially available and has been developed specifically to meet DoD needs under this STTR program.By delivering rugged, low-SWaP protection for mission-critical drone components, this project directly enhances the resilience, lethality, and survivability of U.S. unmanned systems across all theaters of operation. The anticipated outcome is a field-ready capability validated by Air Force stakeholders and a sole-source Phase III transition path for scaled deployment in FY26.