Independent Composites, a UK based provider of high performance composite solutions, is proud to share our role in a groundbreaking scientific milestone: the first successful deployment of a small, wind-powered ocean robot inside a Category 5 hurricane. As part of a collaboration between NOAA, UK-based robotics company Oshen, and the University of Southern Mississippi, a fleet of seven C-Star uncrewed surface vehicles (USVs) was launched to gather real time data during the 2025 hurricane season,

C-Stars are four-foot-long, wind-propelled robots equipped with solar-powered sensors that transmit real-time data every two minutes. These include wind speed and direction, sea surface temperature, air temperature, pressure and humidity, all critical for improving hurricane forecasting and climate modelling. On September 28, one of these four-foot-long, wind-propelled C-Stars became the smallest vessel ever to transmit live data from the eyewall of a Category 5 storm, Hurricane Humberto. Two more entered the storm while it was still Category 4, collecting vital data on wind speed, sea surface temperature, air pressure and more.

At Independent Composites, we supported the construction of the C-Star fleet with advanced composite fabrication and structural expertise.. Our knowledge and design process helped ensure the vessels were lightweight, resilient and capable of withstanding extreme ocean conditions.

As Dan Emuss, Director of Independent Composites, further noted: ““We optimised the core material selection used in the wingsails and manufacturing process to include the CNCing of the foam core material prior to the moulding process, Parts are then moulded from a direct machined mould tool (DTM / Direct-to-Mould) to allow a fast turnaround in order to meet Category 5 Hurricane Humberto and later Hurricane Melissa.”

This collaboration highlights the growing role of advanced composites in marine robotics and environmental monitoring. Independent Composites continues to work with partners across science, defence, and sustainability sectors to push the boundaries of performance at sea.