Continuous Composites received a $750,000 reward for using 3D printing technology to produce

China3D printingNet May 25th, Continuous Composites is a composite material3D printingThe developer of the technology has been awarded a $750,000 contract by the US Department of Defense (DoD) for the second phase of Small Business Innovation Research (SBIR).

The company will use the funds to showcase its proprietary continuous fiber in a collaborative manufacturing project with the Air Force Research Laboratory (AFRL)3D printing(CF3D) technology.These organizations will work together to develop a3D printingMultifunctional composite wing structure.

“The plan to enter the second phase directly provides us with the opportunity to collaborate with this innovative team and its disruptive manufacturing technology to further develop CF3D’s mission preparation capabilities,” said Craig Neslen, head of manufacturing at AFRL. “We are committed to evaluating and perfecting Continuous Composites technology for advanced aerospace structures, which will enable us to meet the challenging manufacturing requirements of the Department of Defense.”



The XQ-58A Valkyrie UAV is a “low-cost” wearable aircraft. Image courtesy of Kratos Defense.


Continuous fiber3D printingofDefense applications

Continuous Composites was founded in 2015. This Idaho-based company claims to have one of the “world’s earliest authorized patents for continuous fiber printing.” Unlike many other composite printing processes, CF3D works by combining continuous fiber reinforced materials with thermosetting resin technology. The CF3D end effector is installed at the end of the robotic arm and is used to co-deposit dry fibers with a fast-curing polymer resin matrix.
The resin-infused fiber cures almost immediately under ultraviolet light, producing anisotropic parts with customizable strength characteristics. CF3D is compatible with all types of optical fibers, including carbon fiber, glass fiber, optical fiber and metal fiber.

In defense applications,3D printingTechnology provides a low-cost, time-saving method to manufacture lightweight, topology-optimized structural components. These advantages are directly in line with the Air Force’s low-cost and wearable aircraft technology/platform (LCAAT/P) program.
“We are honored to be awarded this second SBIR contract directly through the Department of Defense,” added Tyler Alvarado, CEO of Continuous Composites. AFRL is a long-term customer, and he realized the destructive features of CF3D early on. Through this and other contracts, we are committed to transforming the combat capabilities of the Department of Defense. “

CF3D works by depositing and curing continuous fibers infused with resin. Filmed through continuous composite materials.

SBIR Phase 2 Contract

The contract itself involves in a single monolithic wing frame3D printingIntegrated wing spar and rib configuration. Prior to printing, Continuous Composites and AFRL’s Advanced Structural Concepts department will use AI-based generative design software to optimize the geometry of the wing structure. The part will be made of a high-performance thermosetting resin reinforced with continuous carbon fiber-a material developed in collaboration with materials expert Arkema.
Once the production is complete, the3D printingThe frame will be equipped with composite wing skins, making it suitable for use on unmanned aircraft. AFRL will also perform static wing tests to evaluate the performance of the structure, while Continuous Composites will record process data to compare it3D printingThe technology is compared with traditional manufacturing and assembly processes.


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Partners will be in a single part3D printingWing spar and rib configuration. Through continuous composite images.

Composites such as CF3D3D printingTechnology has multiple advantages in terms of cost, delivery time and part characteristics.Earlier this month, Continuous Composites also partnered with energy technology company Siemens Energy to develop3D printingGenerator parts. By using CF3D, the two companies were able to use a special thermosetting glass fiber reinforced polymer material to manufacture generator components.

In other places,3D printingMachine manufacturer Impossible Objects recently signed a joint development agreement with industrial building materials supplier Owens Corning to develop its own dedicated3D printingComposite materials. According to reports, the glass fiber reinforced material will be used in conjunction with the “impossible” composite-based additive manufacturing (CBAM) process, which is said to provide a high strength-to-weight ratio and excellent chemical resistance.

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