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U.S. Air Force backs Continuous Composites in advancing FEA simulation for anisotropic CF3D structures

Development of this FEA tool could solve the gap in simulating high-performance composite parts under various conditions, with potential applications across aerospace, defense and UAV.

Grace Nehls
Edited by:  Grace Nehls
Senior Managing Editor, ÂÌñÏ×ÆÞ and Products Finishing

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FEA heat map shows stress and strain distribution across the geometry under the applied load. Source | Continuous Composites

On Aug. 15, Continuous Composites (CCI, Coeur d’Alene, Idaho, U.S.) was awarded a $1.9 million  contract from the U.S. Air Force to develop a finite element analysis (FEA) tool for Continuous Fiber 3D Printing (CF3D). This contract, which started in November 2024, will run through August 2026, and represents an advancement in the simulation of anisotropic composite materials.

Currently, commercially available FEA solutions are limited to isotropic materials, such as metals, where strength and stress responses are uniform in all directions. However, CF3D composites are anisotropic, with primary strength in the direction of the fibers. This creates a challenge for traditional FEA software, which cannot accurately predict material behavior based on fiber orientation.

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“We’re solving a major gap in FEA simulation tools,” says 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.”

CCI is partnering with industry experts on the development of this FEA tool. It will reportedly ingest CF3D toolpath data to generate mesh representations that more accurately reflect fiber orientation, material behavior and structural performance of how anisotropic parts will react to real-world loads.

What is CF3D?

Continuous Composites’ CF3D technology is a 3D printing process that combines continuous fiber reinforcement with thermoset resins and robotic automation to create strong, lightweight composite parts. It uses a continuous dry fiber that is impregnated with a resin, and then cured with UV light, enabling the creation of complex geometries and the embedding of sensors or circuits. This technology aims to disrupt traditional composites manufacturing by offering a more efficient and cost-effective way to produce high-performance parts, particularly in industries like aerospace and defense. 

Read “Commercializing UV-curable thermosets for continuous fiber 3D printing” for more info.

As part of this effort, CCI will integrate the new tool into CF3D Studio, enabling the prediction of material properties and performance before physical testing begins. This capability is expected to dramatically reduce development time and increase reliability in the design of complex composite parts used in mission-critical applications.

This contract is a milestone for Continuous Composites, advancing CF3D technology from a manufacturing process to a comprehensive design-to-performance solution. 

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