Next Generation Fuselage Structures for Launched Effects

July 24, 2025

Completed Fiber Architecture Leading Edge by Continuous Composites CF3D. (Image: Continuous Composites)

Continuous Composites (CCI) has been awarded a U.S. Army Small Business Innovation Research (SBIR) project in collaboration with Aurora Flight Sciences, a Boeing Company, to develop next-generation fuselage structures for launched effects. The project, which originated as a Navy-funded initiative, was successfully transitioned to the Army following the completion of Phase One and is now entering Phase Two with a $2 million contract.

The initiative focuses on enhancing the structural integrity of systems designed to be launched from canisters — similar to missile deployment systems — and aims to set new performance benchmarks for these air-launched platforms. Aurora is providing critical flight load data and geometric designs, which Continuous Composites will use to develop optimized fuselage structures through its patented CF3D® technology.

Leveraging its expertise in fiber steering and topology optimization, CCI will engineer lightweight, high-performance fuselage designs that maximize internal volume, directly increasing payload capacity without compromising overall performance. This innovative approach reimagines internal architecture, using less material while embedding greater strength into the design, reducing weight and improving efficiency for mission-critical aerospace applications.

“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.”

The SBIR is one of the latest development awards received by Continuous Composites. On July 14, the company announced a multi-million dollar funding award from the U.S. Air Force as part of a multi-year contract to advance the development of high-performance materials using CF3D® technology. This funding is divided into two phases:

The first phase, currently underway, focuses on establishing baseline material properties and a performance validation campaign to benchmark CF3D-produced components against traditional manufacturing methods, such as those used for materials like Carbon-Carbon.

The second phase of the funding will support the expansion of this work, enabling full-scale component production and flight testing. This phase will allow CCI to refine production processes, conduct additional testing, and further advance CF3D's capabilities for high-temperature applications.

CF3D (Continuous Fiber 3D) technology enables the automated manufacturing of continuous fiber composites in near-net shapes, offering precise control over fiber orientation and geometry. This capability facilitates the scalable production of complex parts with enhanced design flexibility and the ability to meet the high-performance requirements of high-temperature applications.

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