Continuous Composites (CCI), a developer of composite 3D printing technologies, has received a $1.9 million Tactical Funding Increase (TACFI) contract from the U.S. Air Force to create a Finite Element Analysis (FEA) tool for Continuous Fiber 3D Printing (CF3D). The project, which began in November 2024 and will run through August 2026, is designed to improve simulation capabilities for anisotropic composite materials, whose strength varies according to fiber orientation.
Currently, most commercially available FEA solutions are designed for isotropic materials like metals, where stress and strength are uniform in all directions. CF3D composites, however, are anisotropic, with primary strength along the fiber paths, creating challenges for traditional FEA software in predicting part performance.
“We’re solving a major gap in FEA simulation tools,” said Steve Starner, CEO of Continuous Composites. “Existing software only assigns a single directional property to each layer of composite material, but CF3D’s fiber steering requires a more dynamic approach. Our new tool will accurately simulate how our parts will behave under various conditions, which is crucial for industries like aerospace and defense.”
Tool Integration and Industry Impact
CCI is working with industry experts to develop the new FEA tool, which will utilize CF3D toolpath data to generate mesh representations that more accurately reflect fiber orientation, material behavior, and structural performance under real-world loads. The tool will be integrated into CF3D Studio, enabling prediction of material properties and performance before physical testing begins, reducing development time and enhancing design reliability.
CCI noted that the contract represents a significant milestone, transforming CF3D from a manufacturing technique into a comprehensive design-to-performance solution. This advancement in simulating high-performance, lightweight composites could impact aerospace, defense, and UAV sectors, enabling the development of mission-critical parts with greater accuracy, reliability, and efficiency.
U.S. Defense Investments in Additive Manufacturing
In related developments, Elementum 3D, a developer of advanced metal materials and print parameters for additive manufacturing, was selected as an EWAAC awardee. The company will contribute its expertise in high-performance materials and AM processes to support projects aligned with the Air Force’s digital transformation and armament modernization goals. The company is known for its proprietary Reactive Additive Manufacturing (RAM) technology, which enables printing of advanced materials previously unattainable with conventional methods.
In June, Divergent Technologies, an AI-driven 3D manufacturing solutions provider, was also selected to participate in the EWAAC program. Divergent’s Adaptive Production System (DAPS) integrates AI-driven design, high-volume additive manufacturing, and robotic assembly to accelerate the development and deployment of next-generation weapons systems.
The EWAAC initiative is a $46 billion multi-award Indefinite Delivery/Indefinite Quantity (IDIQ) contract aimed at accelerating innovation within the U.S. defense sector.
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Featured image shows Heat map showing stress and strain distribution across the geometry under the applied load. Image via Continuous Composites.
