CONTINUOUS FIBER 3D PRINTING Development and Application of Continuous Fiber 3D Printing Process for Aerospace

Accomplishing dramatic reductions in the manufacturing cost of composite structures requires a combination of developments in automated processes, high speed material application and reduced dependence on hard tooling methods. To benefit high performance aerospace applications these developments are best accomplished on processes suitable to continuous fiber composites. The Continuous Fiber 3D Printing (CF3D (R)) process, a newly developed technology for additive manufacturing of continuous fiber composites, offers the combination of necessary attributes to revolutionize the manufacture of low cost, high performance composites. This paper provides a description of the technology, ongoing development efforts, and plans for future improvements and applications. Initial aerospace application is focused on the USAF Low Cost Attritable Aircraft Technology (LCAAT) program, but opportunities for exquisite airframe applications, including cost effective fabrication of topology optimized structures and multifunctional material options is also discussed.