Continuous Composites (CCI) has secured a $1.9 million Tactical Funding Increase (TACFI) contract from the U.S. Air Force to develop a next-generation Finite Element Analysis (FEA) tool for Continuous Fiber 3D Printing (CF3D). The program, launched in November 2024 and running through August 2026, aims to revolutionize the simulation of anisotropic composite materials, which display directional strength based on fiber orientation.

Traditional FEA solutions primarily model isotropic materials such as metals, where stress responses are uniform. However, CF3D composites are anisotropic, requiring simulation tools that account for fiber steering and direction-dependent properties.

We re solving a major gap in FEA simulation tools, said Steve Starner, CEO of Continuous Composites. Existing platforms oversimplify composite behavior, but our new solution will dynamically simulate fiber orientation and structural response, which is critical for aerospace and defense applications.

The new tool will directly ingest CF3D toolpath data to create mesh representations that more accurately reflect real-world performance. Integration into CF3D Studio will enable engineers to predict material properties and part performance before physical testing, reducing development cycles and improving design reliability for mission-critical parts.

This milestone represents a major step in evolving CF3D from a manufacturing process to a full design-to-performance ecosystem, supporting applications in aerospace, defense, and UAV sectors.

Source: continuouscomposites.com