Material Hybrid Manufacturing Receives AFWERX SBIR Phase I Contract to Advance Battery Technology for Extended Drone Operations

February 12, 2025

AUSTIN, TX — Material Hybrid Manufacturing has been selected by AFWERX for a Small Business Innovation Research (SBIR) Phase I contract in undisclosed amount, supporting the development of next-generation conformal battery technology to extend the endurance and operational range of unmanned aerial systems (UAS).

The Air Force Research Laboratory and AFWERX have partnered to streamline the SBIR/STTR process by accelerating the small business experience through faster proposal-to-award timelines, changing the pool of potential applicants by expanding opportunities to small businesses, and eliminating bureaucratic overhead by continually implementing process improvement changes in contract execution. The DAF began offering the Open Topic SBIR/STTR program in 2018, expanding the range of innovations the DAF funds. Now, Material Hybrid Manufacturing will begin work on developing lightweight, high-energy-density battery solutions, designed to enhance mission performance and operational flexibility for next-generation drones and autonomous aerial platforms.

Expanding Drone Capabilities with Advanced Battery Technology

Material’s HYBRID3D™ manufacturing approach allows for precise, conformal energy storage, meaning batteries can be custom-shaped to fit directly into the airframe of drones, reducing weight, improving aerodynamics, and maximizing available power. This breakthrough in battery integration addresses key challenges in drone endurance, range, and payload capacity, offering warfighters and operators a significant tactical advantage.

Quote from Material Hybrid Manufacturing

“We are redefining energy storage for unmanned systems. This AFWERX award enables us to accelerate the development of conformal battery solutions that enhance drone endurance, payload capacity, and overall mission effectiveness. By leveraging additive manufacturing, we can create ultra-efficient, high-performance batteries that seamlessly integrate into aerial platforms, pushing the boundaries of what’s possible in autonomous flight.”

— Gabe Elias, CEO, Material Hybrid Manufacturing

“The views expressed are those of the author and do not necessarily reflect the official policy or position of the Department of the Air Force, the Department of Defense, or the U.S. government.”

About Material Hybrid Manufacturing

Material Hybrid Manufacturing is pioneering 3D-printed conformal batteries to support aerospace, defense, and next-generation mobility solutions. By integrating advanced additive manufacturing techniques, the company develops high-efficiency, mission-adaptive energy storage solutions designed to increase endurance, reduce weight, and optimize performance for aerial and autonomous systems.

About AFRL

The Air Force Research Laboratory (AFRL) is the primary scientific research and development center for the Department of the Air Force. AFRL plays an integral role in leading the discovery, development, and integration of affordable warfighting technologies for air, space, and cyberspace forces. With a workforce of more than 12,500 across nine technology areas and 40+ operations worldwide, AFRL provides a diverse portfolio of science and technology, ranging from fundamental to advanced research. For more information, visit afresearchlab.com.

About AFWERX

As the innovation arm of the DAF and a directorate within the Air Force Research Laboratory, AFWERX brings cutting-edge American ingenuity from small businesses and startups to address the most pressing challenges of the DAF. AFWERX employs approximately 370 military, civilian, and contractor personnel across five hubs and sites, executing an annual $1.4 billion budget. Since 2019, AFWERX has executed over 6,200 new contracts worth more than $4.7 billion, strengthening the U.S. defense industrial base and accelerating the transition of emerging technologies to operational capabilities. For more information, visit afwerx.com.

Company Press Contact

Miles Dotson

Co-Founder and Head of Product, Material Hybrid Manufacturing

Email: hello@materialx.co