Idaho Patent of the Month – September 2025
New 3D printing technology is disrupting composite manufacturing for high-stress applications like aerospace and defense. This method delivers stronger, lighter parts with complex geometries. It represents a fundamental shift away from slow, rigid, conventional composite processes. The innovation, patented by Continuous Composites Inc. , involves a radical approach to combining materials at the point of deposition. The Idaho-based firm is accelerating production and performance across critical industries.
How the CF3D Process Builds Better Parts
The core invention uses a sophisticated co-extrusion system. This process simultaneously deposits two or more materials as a composite path. Specifically, it involves extruding a solid, continuous reinforcing strand. This fiber is completely encased within a second, liquid-form material, typically a proprietary, snap-curing thermoset resin. A curing mechanism hardens the liquid material immediately after extrusion. The continuous strand within the composite path provides specific characteristics like enhanced mechanical or electrical capabilities. This creates multifunctional structures impossible to achieve with single-material 3D printing.
Advancing Next-Generation Manufacturing
The apparatus uses robotics to precisely control fiber placement and tension in three dimensions. This enables the direct fabrication of structural composites without expensive molds or manual layups. The resulting structures boast mechanical performance that rivals metal while maintaining extreme lightweight properties. The patent, U.S. Patent No. 12403651, titled ‘Method and apparatus for continuous composite three-dimensional printing’, secures this critical technology. It lowers manufacturing costs and drastically cuts lead times for mission-critical components, including parts for hypersonics and unmanned aerial vehicles.
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