A Fundamental Shift in Manufacturing

Owning the earliest patents on 3D printing continuous fibers; our technology, Continuous Fiber 3D Printing (CF3D™), constitutes a fundamental shift in the manufacturing process of Advanced Composite Materials (ACM).

Moldless & Out of Autoclave

Our technology utilizes rapid curing thermoset resins with continuous fibers creating a moldless, Out of Autoclave (OOA), composite manufacturing process. CF3D™ impregnates the fiber within the head and cures immediately after material deposition. As a result, we can take full advantage of the anisotropic properties of composite materials by discretely orienting fibers for three-dimensional load path optimization. This enables CF3D™ to create complex, composite structures, without molds or other support materials.

1

New Design Capabilities

Continuous Fiber 3D Printing (CF3D™) is not limited to stacking two-dimensional slices and creates an entirely new manufacturing class of its own. Many of the traditional constraints on design for manufacturability are eliminated by CF3D™. Additionally, the latest advancements in design software’s like generative design and topology optimization can now be truly leveraged.

2

Embedded Functionality

CF3D™ enables printing with both structural and functional fibers into new parts or retrofit applications. Metallic wires and fiber optics can now be simultaneously printed into the composite structure. This introduces the ability to sense and collect data, power electronics, integrate heat applications and embed real-time health monitoring.

3

The Shift

Problem

Traditional composites manufacturing processes are labor intensive and require expensive capital equipment. Additionally, due to the high cost of tooling, the barrier to entry for creating a new composite part or changing the design of an existing composite part is significant.

Solution

CF3D™ is revolutionizing manufacturing by combining the power of composite materials with Additive Manufacturing and advanced robotics. Our technology is the most advanced automated placement of fiber, enabling on the fly design changes and eliminating the need for expensive capital equipment and costly retooling.

Materials

Continuous Fiber 3D Printing (CF3D™) has extensive material options. We can formulate resins to meet specific performance properties with the flexibility to print with any continuous fiber. Here are some of the continuous fibers we are currently printing with:

Carbon Fiber
Fiberglass
Kevlar
Fiber Optics
Copper Wire
Nichrome Wire

Industry Applications

The unprecedented adaptability and versatility realized through our multi-material, free space composite manufacturing methods allows CF3D™ to be applied to a diverse range of markets. Our technology provides novel solutions and new opportunities to a variety of industries and applications.

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Aerospace
Automotive
Construction
Energy
Sporting Goods

Patent Portfolio

Our robust portfolio of patents protect all aspects of CF3D™, with a priority date as early as August 29th, 2012. Our portfolio is constantly growing, and currently includes at least the following:

11
Granted Patents
90
Pending Non-Provisional Patent Applications
15
Provisional Patent Applications, covering 250+ Concepts
46
Pending PCT Patent Applications

Areas of Patent Protection

CF3D™ Processes and Software:
  • Aspects of Printing
  • Positioning
  • Splicing
  • Cutting
  • Curing
  • Shaping
  • Tensioning
  • Compacting
  • Teasing
  • CF3D™ Software
CF3D™ System Hardware, Materials and Applications:
  • Print Heads
  • Nozzles
  • Resins
  • Filaments
  • Vehicle Bodies
  • Sporting Equipment
  • Building Structures
  • Protective Gear
  • Wiring Harnesses
  • And more...

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