Dual Advancing Structural Freedom for Mission-Scale Systems
From Design to Deployment
Defense systems are advancing faster than traditional manufacturing can keep pace. Programs now require structures that are lighter, stronger, multifunctional, and producible across distributed environments. CF3D® was built for this shift—linking design intent to final performance through automated continuous fiber deposition, proprietary material systems, and software that controls fiber architecture with precision.
THE RESULT: mission-ready composite structures engineered for performance, validated through government programs, and positioned for transition to fielded systems.
Advancing CF3D for Mission-Critical Applications
Continuous Composites is executing active prime contracts across the U.S. defense innovation ecosystem. These programs apply CF3D® technology to critical manufacturing challenges spanning hypersonics, precision strike systems, launched effects, design optimization, structural joining, and multifunctional materials.
Each effort advances the materials, software, processes, and production capabilities needed to transition continuous fiber additive manufacturing from development to mission-scale deployment. Check out the SBIR Awards
Continuous Fiber Additive Manufacturing Launch Effects
Amount: $1,999,823 Topic: N231-069
In collaboration with Aurora Flight Sciences, this Phase II program uses CF3D fiber steering, topology optimization, and FEA to develop lightweight, high-performance fuselage structures for launched effects.
SBIR | Phase II | 2025 | DOW | ARMY
Advanced Joining Methods using Automated CF3D Fiber Steering Technology
Amount: $1,245,037 Topic: AFX255-DPCSO6
This Phase II program applies CF3D Enterprise and CF3D Studio to develop fiber-steered composite structures with improved bonding interfaces, structural integration, and unitization for aerospace vehicles and space structures.
SBIR | Phase II | 2025 | DOW | USAF
Continuous Fiber Additive Manufacturing Design Optimization and FEA Integration
Amount: $1,899,999 Topic: AF203-DCSO4
This U.S. Air Force TACFI program integrates anisotropic topology optimization and finite element analysis with CF3D Studio™, enabling engineers to design, predict, manufacture, and validate complex fiber-steered structures.
SBIR | Phase II | 2024 | DOW | USAF
Materials and Manufacturing Processes for sensors, power, and communications of Unmanned Aerial Systems (UAS)
Amount: $139,119 Topic: N232-086
This U.S. Navy program evaluates CF3D for integrating structural reinforcement with sensors, communications, and other functional materials in UAS structures through simulation, coupon testing, and subscale validation.
SBIR | Phase I | 2024 | DOW | NAVY
Continuous Fiber Additive Manufacturing of US Navy Propulsion Shafting
Amount: $144,651 Topic: N231-047
This U.S. Navy program evaluates CF3D for manufacturing large, thick-walled composite propulsion shafts through torsional testing, material-property characterization, process scaling, and representative shaft builds.
SBIR | Phase I | 2023 | DOW | NAVY
Topology Optimized High-Rate, Reduced Life Cycle Cost Airframe using CF3D
Amount: $144,459 Topic: N231-069
This U.S. Navy program develops topology-optimized, fiber-steered stiffened structures for UAV airframes, targeting higher structural performance, faster manufacturing, reduced material waste, and lower life-cycle cost.
SBIR | Phase I | 2023 | DOW | NAVY
Additive Manufacturing of Low CTE Open Isogrid Composite Structure
Amount: $149,854 Topic: S12
This NASA program uses CF3D to manufacture lightweight, open-isogrid carbon fiber structures with a low coefficient of thermal expansion for dimensionally stable space applications.
SBIR | Phase I | 2022 | NASA
Continuous Fiber Thermoset 3D Additive Manufacturing For Rapid Low Cost Structural Composites
Amount: $749,995 Topic: AF203-DCSO4
This U.S. Air Force Phase II program advances continuous fiber thermoset additive manufacturing for the rapid, cost-effective production of high-performance structural composite components.
SBIR | Phase II | 2021 | DOW | USAF
Topology Optimized Wing
Demonstrates optimized fiber steering for superior strength-to-weight performance using topology-optimized design principles.
MATERIAL
- Fiber: Hexcel IM7-12K
- Resin: PolyMat™ High Tg
HIGHLIGHTS
- Performance Advantage — Reduction in fasteners and joints yields significant time and weight savings compared to traditional assembly methods.
- Optimized Part Design — Continuous fibers are steered along load paths to maximize strength and stiffness while unitizing geometry for improved structural efficiency.
Steered Lug Element
Demonstrates advanced methods for capturing steered fibers around fastening features to enhance joint performance.
MATERIAL
- Fiber: Toray T1100SC-12K
- Resin: PolyMat™ High Tg
HIGHLIGHTS
- Performance Advantage — Fiber steering enables precise reinforcement and load distribution around hardware interfaces, improving strength and fatigue resistance.
- Optimized Part Design — Integrating hardware within the print streamlines assembly, reduces secondary bonding, and enhances structural continuity.
Meet With Our Technical Team
Share your application requirements with our engineering team and explore whether CF3D is the right manufacturing approach.