Fire-and electromagnetic interference (EMI)-resistant aircraft components and methods for manufacturing the same

A method for manufacturing a fire- and EMI-resistant aircraft component comprising the steps of:

• forming an additive-manufactured intermediate article comprising a polymeric material;
• integrating a continuous electrically conductive filament within a substrate of the polymeric material during the forming of the additive-manufactured intermediate article such that the continuous electrically conductive filament extends from one end of the additive-manufactured intermediate article to another end of the additive-manufactured intermediate article;
• applying a thermally and electrically conductive coating material layer on the additive-manufactured article forming a coated article, the thermally and electrically conductive coating material layer comprising a metal;
• and
• cold spraying a fire retardant material layer on the coated article,
• wherein the integrating the continuous electrically conductive filament within the substrate of the polymeric material during the forming of the additive-manufactured intermediate article comprises:
• substantially simultaneously feeding a filament of the polymeric material and the continuous electrically conductive filament through a dual extrusion head of a fused deposition modeling system.