Continuous Composites is at the forefront of innovation, introducing novel ways to reduce costs in composites manufacturing through its groundbreaking CF3D® printing technology.

By Jennifer Ferrero

Aerospace applications for high-temperature composites are rapidly expanding. From defense to UAVs and even hypersonic applications, composites need to be more cost effective, faster to build, and withstand high temperatures for the long haul. Continuous Composites (CCI) is leading the way in this transformation. Operating in start-up mode out of Coeur d’Alene, Idaho since 2012, CCI installed its first fully automated CF3D® Enterprise system for a customer in 2022.  Since then, they have developed a seamless yet adaptable software solution for the CF3D® system, enabling engineers to easily design optimized structures.

To this day, President and CEO Steve Starner believes that, despite producing both manufacturing equipment and software for customers, they are still very much a start-up. VP of Sales Josh Randles echoed that sentiment, saying, “A key part of our culture is solving industry challenges with new products and materials that offer practical value propositions.” He added that they are focused on “delivering within shorter design cycles to reduce production costs while increasing scalability and part performance.” This approach is designed to drive significant growth in their customer base and expand their market presence.

True to their start-up roots, Continuous Composites is focused on refining its hardware and software through direct engagement with early adopters. With CF3D® systems already operating at leading research institutions and defense organizations, the company is applying real-time customer feedback to accelerate product evolution and expand strategic deployments.

Benjamin Garcia, a key figure at the Miller Advanced Research and Solutions Center (MARS) at Weber State in Utah, plays a crucial role in the collaboration between the university and industry. His team focuses on next-generation manufacturing equipment for advanced composites, and they have been instrumental in testing and providing feedback on the CF3D® system developed by CCI. “We work closely with Continuous Composites to evaluate the equipment and refine its capabilities,” Garcia said. “Ultimately, our goal is to provide a service that transitions this technology into an industrial partner’s production environment, helping them scale operations.”

At Weber State, they refer to the process as “continuous fiber manufacturing, using the Continuous Fiber Additive Manufacturing (CFAM) robot” — which is the CF3D® Enterprise — to test high-temperature capabilities. Garcia’s team uses this system to create composite structures for high-temperature aerospace applications, including thermal protection systems (TPS), utilizing both polymer and ceramic matrix composites. After using the equipment for about a year, Garcia has seen significant improvements in performance and the advancements it has enabled in their research.

Weber State’s MARS facility serves as a demonstration platform for next-generation manufacturing equipment. By partnering with industry, government, and other national laboratories, they design and build parts that can be deployed in production environments. The Center offers a “try-before-you-buy” model, allowing industry partners to test the technology before making a commitment to purchase.

During his visit to Continuous Composites in 2023, Garcia was impressed by the technical advancements and the shift away from traditional pre-preg systems. “I was impressed with the quality of the product coming out of the machine,” he said. The CF3D system significantly reduces the cost and complexity of sourcing pre-preg materials, a common challenge in traditional composite manufacturing methods.

Traditional composite manufacturing techniques, such as hand layup and resin transfer molding, are labor-intensive, requiring fibers to be manually placed in molds and resin applied either by hand or injection. These methods often involve complex tooling, long lead times, and curing in autoclaves or ovens, making them slow and costly. In contrast, CF3D automates the process by depositing continuous fibers — such as carbon or glass — impregnated with UV-curable resin. Using real-time fiber steering and instant curing with UV light, the system enables faster production. “It’s like a CAD program,” Garcia said, “where you load the design, define the fiber direction, and the machine automatically prints the part to specification.” This approach optimizes strength-to-weight ratios, reduces material waste, and offers a faster, more efficient alternative to traditional methods, making it especially advantageous for industries like aerospace, defense, and UAVs.

By partnering with customers like MARS, CCI is advancing the adoption of 3D-printed composite components, offering a compelling alternative to traditional composites and even metal materials.

Starner explained that industries traditionally reliant on metals for certain applications can now benefit from their technology, adding, “We are uniquely positioned to replace metals with advanced composite solutions.” This shift results in lighter, stronger parts, optimized performance through load-aligned fibers, and more efficient material use, with the potential for up to a 2X increase in strength and stiffness compared to conventional metals. Starner emphasized that this approach allows for faster product design cycles while unlocking “new mission capabilities” in a scalable and cost-effective way.

The benefits of CF3D printing are numerous:

• High Strength, Low Weight
• Cost-Efficient
• Fully Automated
• Design Flexibility
• Maximum Material Efficiency
• Fast Iteration
• Affordable Dry Fibers
• No Hand Layup Required
• Near-Net Shapes
• Unlimited Material Options
• Limitless Material Combinations

As for company growth, Randles shared, “We are growing. We are very excited and very happy with where we are today. We continue to solve new problems, bring in new contracts, and continue to grow our team.”

“With a team of engineers, builders, and problem solvers, it’s only natural that a key part of our culture is solving problems we deeply understand and using that knowledge to grow revenue,” Starner said. This mindset fuels the development of new products and materials that offer practical value, speeding up design cycles and enabling more scalable, cost-effective, high-performance parts.

Patents and patent applications held by Continuous Composites:

• 122 Allowed U.S. patents
• 207 U.S. non-provisional applications
• 49 U.S. provisional applications
• 72 International PCT applications
• 44 Granted international patents

Contact Information

• Address: 216 E Coeur d’Alene Ave. Coeur d’Alene, ID 83814
• Phone: 1 (888) 508-1085
• Email: info@cf3d.com