Conformal Batteries for Class I Drone Applications

Small unmanned aerial systems (sUAS), particularly Class I Group 1 drones, have become ubiquitous in modern warfare—used for ISR, electronic warfare, and increasingly, as lethal platforms. As the Air Force moves toward distributed, autonomous drone operations, energy availability has become an existential constraint. Without significant gains in battery energy density, these systems will continue to face mission-limiting tradeoffs between flight time, payload, and maneuverability. Most current drone batteries rely on foreign-made cylindrical cells designed for consumer devices. These rigid packs waste valuable space, reduce endurance, and require payload compromises. Worse, their sourcing from adversarial regions introduces unacceptable supply chain risk—particularly during surge deployments, forward operations, or export-controlled missions. These limitations have been confirmed through direct engagement with DAF stakeholders, including personnel from the 21st STS, 18th ASOG, and 5th SFG. Material’s HYBRID3D™ platform solves this by 3D-printing conformal lithium-ion batteries with up to 55% more pack-level energy density and 22–25% weight reduction. Critically, our form-fitting packs can match the volume and connector profiles of existing drone battery modules—allowing for drop-in replacements without modifying the drone airframe. This enables rapid integration and operational use on platforms currently procured without the delays or requalification costs of full system redesigns.