Dual Polymer Matrix Composites (PMC)
CF3D® technology, powered by the PolyMat™ resin family, enables the fabrication of advanced PMCs with exceptional strength-to-weight performance and design freedom. Continuous fiber printing delivers lightweight, high-strength structures precisely tailored for demanding aerospace, defense, and high-performance applications.
Structural Aero Applications
- Lightweight, high-strength components for airframes and interior structures
- Continuous carbon and glass fiber reinforcement using PolyMat resins
- Maintains structural integrity under dynamic loads and high stress
UAV and Autonomous Systems
- Optimized stiffness-to-weight for agile, extended-range platforms
- Ideal for airframes, payload housings, and wing structures
- Integrates sensors and wiring seamlessly through CF3D design flexibility
Propulsion and Energy Systems
- Precision-printed casings, supports, and thermal-resistant hardware
- Tailorable mechanical and thermal properties for performance and reliability
- Near-net-shape production enhances efficiency and reduces assembly
Multi-Functional Integration
CF3D enables the creation of multi-functional composites by embedding structural and functional materials within a single print process. Continuous fibers, wiring, optical fibers, and sensing elements are deposited together—precisely placed and cured in-situ—to form load-bearing parts with integrated intelligence. From structural power routing and strain measurement to thermal sensing and data transmission, CF3D produces components that go beyond structure—they perform. This embedded functionality reduces part count, eliminates secondary assembly, and enhances system-level performance.
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.
Cured Neat Resin Properties
|
Properties |
Method |
|
|
Solid Density (g/cc) |
ASTM D-792 |
1.22 g/cm^3 |
|
Glass Transition (°C) |
DMA |
230°C |
|
Working Max Temp (°C) |
DMA |
179°C |
Composite properties normalized to 50% FVF CF3D Certified Fibers with PolyMat™ High Tg (UV snap cure + post bake).
Properties tested under room temperature dry conditions:
| Properties | Method | |
| 0° Tensile Strength (MPa) | ASTM D-3039 | 2,030 |
| 0° Tensile Modulus (GPa) | ASTM D-3039 | 114.87 |
| 90° Tensile Stress (MPa) | ASTM D-3039 | 27 |
| 90° Tensile Modulus (GPa) | ASTM D-3039 | 6.44 |
| 0° Compressive Strength (MPa) | ASTM D-6641 | 549 |
| Compressive Modulus (Mpa) | ASTM D-6641 | 112.01 |
| 0° Flexual Strength (MPa) | ASTM D-6641 | 978 |
| Flexual Modulus (GPa) | ASTM D-790 | 83.61 |
| In-Plane Shear Strength (MPa) | ASTM D-790 | 48.94 |
| In-Plane Shear Modulus (Gpa) | ASTM D-3518 | 3.22 |
| Short Beam Shear (MPa) | ASTM D-3518 | 62 |
| Qi Compression Stress (MPa) | ASTM D-2344 | 325 |
| Qi Tension Strength (Mpa) | ASTM D-6641 | 646 |
| Open Hole Tensile (MPa) | ASTM D-3039 | 646 |
| Open Hole Compression (MPa) | ASTM D-5766 | 213 |
| Single Shear Bearing Test (MPa) | ASTM D-5961 | 611 |
Advantages of Our PMC Approach
EFFICIENCY
CF3D combines real-time deposition and snap-curing to produce structural composites without the delays of conventional layups or autoclave cycles—accelerating production and shortening lead times.
CUSTOMIZATION
Polymer matrices and continuous fibers—carbon, glass, or aramid—are tailored to achieve precise mechanical, thermal, and durability requirements for each application.
SUSTAINABILITY
Near-net-shape CF3D preforms minimize material waste and energy consumption, offering a cleaner, more efficient alternative to traditional PMC processes such as hand layup or resin transfer molding.
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.