Continuous Composites has secured a U.S. Army Small Business Innovation Research (SBIR) Phase Two project, in partnership with Aurora Flight Sciences (a Boeing Company), to develop advanced fuselage structures for air-launched effects. Originally funded by the U.S. Navy, the project has now transitioned to the Army after a successful Phase One and is supported by a $2 million contract.
The project centers on enhancing the structural design of systems launched from canisters—akin to missile systems—by employing Continuous Composites’ proprietary CF3D® (Continuous Fiber 3D Printing) technology. Aurora is contributing vital data on flight loads and geometric design inputs, which will serve as the foundation for the optimized structural designs.
Continuous Composites will apply its expertise in fiber steering and topology optimization to engineer lightweight, high-strength fuselages that maximize internal space, thereby improving payload capacity without sacrificing performance. This innovation allows for a more efficient use of materials while achieving greater strength and structural integrity, a crucial advancement for aerospace and defense sectors.
“This collaboration represents a powerful convergence of aerospace innovation and cutting-edge manufacturing technology,” said Steve Starner, CEO of Continuous Composites. “By pairing Aurora’s flight systems expertise with our CF3D technology, we are pushing the limits of what’s possible in the development of launched effect structures, delivering more agile, functional, and cost-effective solutions for defence applications.”