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.

“By merging our CF3D platform with Aurora’s flight-proven systems, we’re building the future of deployable aerospace structures,” said Steve Starner, CEO of Continuous Composites. “This contract represents 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