The Navy, in partnership with Skydweller Aero, completed a 73-hour continuous solar-powered unmanned flight during a three-day test from Stennis, Mississippi. Led by the Naval Air Warfare Center Aircraft Division at Patuxent River, the demonstration advances long-endurance solar-powered UAS technology and its role in maritime intelligence, surveillance and reconnaissance.
The test validated the Skydweller solar-powered UAS ability to sustain solar-powered operation, achieve positive energy balance for extended flights, maintain communication links, make autonomous decisions in real time and handle turbulent weather. The flight path traced the letters USA over the Gulf of Mexico and southeastern United States, highlighting precise navigation, as detailed in the official Navy announcement.
“This demonstration is a prime example of how NAWCAD partners with industry to deliver what the fleet needs,” said NAWCAD Commander Rear Adm. Todd Evans. “It also reflects the technical depth of our workforce and our ability to translate ideas into capability.”
Integrating the solar-powered UAS into Navy ISR systems creates a layered network, allowing advanced assets to focus on rapid response missions. “Integrating Skydweller into the Navy’s ISR architecture creates a layered and resilient network that maximizes the capabilities of all our assets,” says NAWCAD’s Special Purpose UAS lead Bill Macchione. “This collaborative approach ensures we have the right platform for the right mission, optimizing our resources and enhancing our overall maritime domain awareness.”
The solar-powered UAS provides wide-area surveillance over long periods, freeing specialized systems for other tasks. NAWCAD initiated experiments with Skydweller solar-powered UAS in 2020 to tackle U.S. Southern Command challenges like drug trafficking and border security. The technology enables ongoing monitoring of vast regions, aiding the U.S. and allies in boosting maritime security and countering illegal operations. Additional testing is scheduled later this summer in the Southern Command area.
The Skydweller solar-powered UAS stems from the Solar Impulse 2 aircraft, which completed the first solar-powered circumnavigation of the Earth in 2016 over 17 segments, according to aerospace technology reports. Skydweller Aero acquired and converted it to an unmanned platform in 2019, removing the cockpit and adding autonomous controls, as noted in company development updates. The aircraft features a wingspan exceeding 72 meters, greater than that of a Boeing 747, weighs about as much as a Ford F-150 truck at around 2,550 kilograms, is built from carbon fiber and can carry payloads up to 400 kilograms, per detailed specifications in defense aviation analyses. It operates at altitudes up to 45,000 feet, produces no carbon emissions and costs 10 to 100 times less for long missions than traditional aircraft, based on operational efficiency studies.
The solar-powered UAS combines artificial intelligence with aerospace advancements, drawing on global investments in solar energy, batteries and carbon fiber production. Its perpetual flight potential replaces fleets of conventional aircraft, reducing operational expenses and environmental impact. Customers envision uses in detecting smugglers at sea, providing coverage over conflict zones and monitoring wildlife.
The test forms part of a Joint Concept Technology Demonstration by the Office of the Undersecretary of Defense for Research and Engineering, continued via a Cooperative Research and Development Agreement with NAWCAD, as outlined in military test evaluations. In June 2025, Skydweller partnered with Thales to integrate AirMaster S radar, improving ISR with AI for target classification, according to industry partnership announcements.
NAWCAD, based in Patuxent River, operates test ranges, labs and aircraft for Navy and Marine Corps aviation development. It employs military, civilian and contract staff across sites including St. Inigoes, Lakehurst and Orlando. Naval Air Station Patuxent River hosts over 25,000 personnel, making it a key economic driver in St. Mary’s County with annual appropriations exceeding $40 billion and serving as the Navy’s busiest flight test center.
In Southern Maryland, NAWCAD supports high-tech jobs and community growth. The region’s proximity to the Chesapeake Bay and Patuxent River facilitates aviation testing, contributing to local employment and expertise in unmanned systems. This solar-powered UAS milestone underscores Patuxent River’s leadership in innovative defense technologies, benefiting maritime operations worldwide.
The demonstration highlights procedural advancements in autonomous flight, from energy management to weather adaptation, setting stages for broader solar-powered UAS adoption. As testing progresses, the technology promises enhanced domain awareness without crew risks, aligning with Navy priorities in efficiency and sustainability.