Continuous Composites Inc.

Continuous Composites Inc., headquartered in Coeur d'Alene, Idaho, manufactures continuous fiber additive manufacturing systems and advanced composite structures for federal defense and aerospace research, operating as a small business prime contractor on 77% of its recent federal awards and competing predominantly under total small business set-asides across Air Force, Army, and Navy R&D programs.

Continuous Composites specializes in continuous fiber three-dimensional (3D) printing technology and design optimization for high-performance composite structures, low coefficient of thermal expansion materials, and advanced joining methods. The vendor's capability portfolio centers on research and development across continuous fiber additive manufacturing (CF3D), hypersonic structural materials development, topology-optimized composite components, and finite element analysis integration for defense applications. Representative prime contracts include a $16.89 million firm fixed-price multiyear development contract awarded by the Air Force Research Laboratory on May 3, 2024, for CF3D multiyear development focused on hypersonic structural materials with performance through November 3, 2025 (no set-aside used); a $4.34 million AFRL contract for design optimization and finite element analysis integration of continuous fiber additive manufacturing, running through May 2028; a $2 million Army SBIR Phase II contract awarded November 2024 for continuous fiber additive manufacturing launch effects research, extending through November 2026; and a $1.25 million AFRL SBIR Phase II award from September 2025 for advanced joining methods using automated continuous fiber 3D printing and fiber steering technology, completing December 2026. Work is performed at facilities in Coeur d'Alene and Dalton Gardens, Idaho.

Customer concentration is heavily skewed toward Air Force research. The Air Force Research Laboratory accounts for 6 awards and $23.2 million of the vendor's $26.9 million combined potential value across thirteen total awards (85% of award count). The Department of the Navy (Naval Air Warfare Center, Naval Sea Systems Command, and Office of Naval Research combined) places two SBIR awards totaling approximately $1 million, the Department of the Army holds one award of $2 million, and NASA's Shared Services Center holds one award of $150 thousand. The top five customer agencies cover 99% of combined potential value. Activity has grown from two awards in 2022 to four in 2024, with three awards (combined potential value $7.6 million) reaching ultimate completion within the next twenty-four months and facing recompete exposure. One IDC (Indefinite Delivery Contract FA865020D5211) appears in the top parent vehicles block.

Continuous Composites subcontracts engineering services to the University of Dayton on two awards addressing disruptive composites technologies for attritable and rapidly deployable vehicles and advanced behavior and life prediction of aerospace high-temperature composites (March 2022 and December 2021), and serves as sub-recipient to the National Center for Defense Manufacturing and Machining on a federal grant sub-award (January 2024). The vendor's award footprint reflects persistent focus on SBIR Phase I and Phase II contracts across the Department of Defense and NASA, with recent expansion into larger development contracts at AFRL anchoring dollar growth.