Additively Manufactured Embedded Wiring Harnesses

To address the NavyÆs need for novel UAV multifunctional weight-saving structural technologies, Impossible Objects proposes to use its novel composite additive manufacturing technology to embed wire harnesses into structural UAV parts. If successful, this will be the first scalable method to integrate high-current wiring into high-strength lightweight composite parts using a high-volume manufacturing process. While providing weight savings, this added capability will add many additional functionalities. In particular, it will also enable near frontline manufacturing in areas affected by contested logistics with volumes measured in thousands of UAVs per printer per month, while also a) reducing the heat signature of the UAV and allowing for electrical redundancy at no additional cost or impact to throughput, b) greater UAV robustness, c) lower drag, and d) far lower assembly times. In Phase I, Impossible Objects will demonstrate that high current wiring can be embedded into their parts and characterize the impact, if any, to the material performance. In Phase II, this will be extended to embed a full wiring harness in a UAV chassis and prove out the scalability of the manufacturing process.