J.W. van Egmond
WovenStrong, LLC,
United States
Keywords: additive manufacturing, 3d weaving, light-weighting, airframes, UAVs, drones
Summary:
WovenStrong introduces a new class of additive composite manufacturing called 3D Ribbon Weaving (3DRW), a patented process that integrates weaving, additive manufacturing, and composite engineering to produce lightweight, high-strength airframes for drones and aircraft (US20240384522A1 and WO2025179047A1). Until now the shapes possible with ribbon weaving have been limited to two dimensional surfaces, either flat or curved shells, such as baskets. 3DRW is a fundamental breakthrough technology because for the first time it is possible to weave structures with surfaces that branch off into the third dimension. This enables weaving of structures such as light yet strong lattices of interconnected tetrahedra or shells with internal structure. Almost any type of shape can be made with 3DRW including shapes relevant to aerospace, such as wings, tail sections or potentially entire airframes. The technology interlaces ribbons of material into continuous, aerodynamic interconnected shell structures that eliminate weak joints and provide superior load distribution, impact resistance, and stiffness-to-weight ratios. Many types of materials can be used, including metals, carbon fiber composites and polymers. Unlike conventional drone frames built from bolted arms, molded shells, or 3D printed segments, 3DRW constructs the entire airframe as a unified woven body. Each ribbon is algorithmically cut and interlocked to form a stable tetrahedral lattice network. This architecture holds itself together by mechanical interference, even without adhesives or fasteners. The result is an airframe that is stronger, lighter, and faster to manufacture, while maintaining precise geometric control and aerodynamic smoothness. WovenStrong’s process operates at the intersection of digital design and scalable fabrication. Using generative algorithms based on the target article's shape, ribbon shapes can be tailored to form complex geometries such as integrated wings, fuselages, or curved payload shells. Because ribbons are woven of material that is already in the form of a sheet, rather than printed layer-by-layer, manufacturing is faster. Currently in the prototyping stage, WovenStrong is building carbon-fiber woven drone frames to outperform conventional skeleton-arm designs in weight and impact resistance. A prototype quadcopter airframe constructed with six interwoven ribbons is designed for superior strength-to-weight performance and minimal aerodynamic drag. The goal is also improved payload capacity, agility and/or flight endurance due to reduced structural mass. The technology is directly relevant to defense, aerospace, and commercial UAV markets, where performance, weight, and manufacturing speed are mission-critical. Users require UAVs that can survive impact, withstand harsh weather, and deploy rapidly at scale, all of which 3DRW enables. The process also supports customizable, multifunctional structures, with built-in channels for wiring, cooling, or stealth integration through assemblies of flat panels. Beyond UAVs, the 3DRW platform extends to aircraft panels, marine hulls, and automotive shells, supporting broader industry trends toward digital, distributed, and sustainable manufacturing. By merging advanced materials science with geometric computation, WovenStrong bridges the gap between high-performance composites and scalable production. This technology represents a paradigm shift in airframe manufacturing, unlocking new possibilities for efficiency.