U.S.-based company Continuous Composites, in collaboration with Aurora Flight Sciences—a Boeing subsidiary—is developing new structural concepts for air-launched systems deployed from launch canisters. As part of a U.S. Army Small Business Innovation Research (SBIR) program, the project has entered Phase Two and received $2 million in funding. The goal is to develop lightweight yet high-strength fuselage structures for so-called “launched effects”—unmanned platforms designed for mission-specific deployment from tubes or containers.
At the heart of this collaboration is Continuous Composites’ CF3D (Continuous Fiber 3D Printing) technology. This additive manufacturing method enables the production of fiber-reinforced polymer components using continuous fiber materials, while offering high geometric freedom. CF3D allows load-optimized fiber paths to be embedded directly into the structure in a single manufacturing step, without relying on traditional tooling or autoclaves.
Aurora provides the geometric data and aerodynamic load profiles, while Continuous Composites handles the structural implementation. Through topology optimization and precise fiber orientation, the components are designed to achieve maximum mechanical strength with minimal material usage. This not only reduces launch mass, but also allows for increased internal volume for sensors or other payloads.
“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 defense applications.”
With this latest round of funding, the U.S. Army is highlighting the potential of CF3D technology for the future of defense systems.
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