Independent Composites, a UK-based specialist in high-performance composite engineering, is proud to announce its contribution to a landmark scientific achievement: the first successful deployment of a small, wind-powered ocean robot inside a Category 5 hurricane.

As part of a collaboration between the National Oceanic and Atmospheric Administration (NOAA), UK robotics firm Oshen, and the University of Southern Mississippi (USM), a fleet of seven C-Star uncrewed surface vehicles (USVs) was launched to gather real-time data during the 2025 hurricane season.

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 Hurricane Humberto — a Category 5 storm. Two additional C-Stars entered the hurricane while it was still Category 4, collecting vital meteorological data including wind speed and direction, sea surface temperature, air pressure and humidity.

Independent Composites played an important role in enabling this mission by delivering precision-engineered composite components for the C-Star fleet. The company’s expertise in materials selection, tooling and rapid manufacturing was essential to ensuring the vessels could withstand the extreme conditions of open-ocean hurricane deployment.

As Dan Emuss, Managing Director of Independent Composites, 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 approach enabled Oshen to meet tight deployment timelines while ensuring structural integrity and performance under the most demanding conditions on Earth. The success of the C-Star fleet demonstrates the critical role of advanced composites in next-generation 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 delivering solutions that are lightweight, resilient and built for impact.

For more information on Oshen and their current projects please visit oshendata.com.