Continuous Composites (CCI), a pioneer in additive composite manufacturing, has secured a $2 million Phase II Small Business Innovation Research (SBIR) contract from the US Army to develop next-generation fuselage structures for launched effects platforms. The project is being executed in partnership with Aurora Flight Sciences, a Boeing subsidiary known for its expertise in advanced aerospace systems.
Originally funded by the US Navy, the initiative completed Phase I and has now transitioned to the US Army for expanded development. The program is focused on enhancing the structural efficiency and performance of air-launched platforms deployed from canisters, akin to missile systems. These launched effects platforms are a critical component in modern battlefield intelligence, surveillance, and reconnaissance (ISR) operations.
Continuous Composites will apply its patented Continuous Fiber 3D Printing (CF3D) technology to design and manufacture topology-optimized, lightweight fuselage structures. Aurora Flight Sciences will provide essential flight load data and geometric specifications, allowing CCI to tailor composite architectures to real-world aerodynamic and structural demands.
Steve Starner, CEO of Continuous Composites, said merging the CF3D platform with Aurora's flight-proven systems represents building the future of deployable aerospace structures, calling the contract a major milestone in delivering scalable, lightweight solutions to the U.S. defense sector.
CCI's approach leverages advanced fiber steering techniques and real-time control to deposit continuous carbon fiber into structurally efficient geometries. This enables the design of fuselages that maximize internal payload volume while reducing weight and material usage, a critical advantage for air-launched systems requiring compact, durable, and agile designs.
The award is also a significant endorsement of CF3D's readiness for high-performance defense applications. As launched effects platforms continue to evolve for autonomous, swarming, and multi-domain operations, this project marks a pivotal step toward next-gen composite structures that are both functionally superior and logistically streamlined.
Source: www.continuouscomposites.com
