Continuous Composites Triples Production Space to Meet Defense Demand

COEUR D'ALENE, ID – April 20, 2026 – In a move that signals a significant shift from research and development to full-scale production, Continuous Composites has relocated its operations to a new 17,000-square-foot facility in Coeur d'Alene. The expansion, which more than doubles the company's manufacturing footprint, is a direct response to escalating demand for its advanced composite manufacturing technology in the aerospace, defense, and high-performance sectors.

The new site, located at 3875 N Schreiber Way, provides the company with an 11,000-square-foot production warehouse and 6,000 square feet of office space—a dramatic increase from its previous 5,500-square-foot location downtown. This expansion is designed to accommodate the growing need for its patented Continuous Fiber 3D Printing (CF3D) systems, which are poised to disrupt how critical components are designed and built.

"We're building a manufacturing technology intended to support the warfighter, and that requires scale," said Steve Starner, CEO of Continuous Composites. "Our previous footprint limited how many systems we could build and support in parallel. This expansion gives us the space to increase production, allowing us to produce 5x more components and systems, while also giving customers more direct access to the people and infrastructure behind the technology."

A Leap in Manufacturing Technology

At the heart of this expansion is the company's groundbreaking CF3D technology. It represents a fundamental departure from traditional composite manufacturing, which often relies on slow, expensive, and design-limiting processes involving molds, pre-impregnated materials (pre-pregs), and large industrial ovens or autoclaves.

CF3D utilizes a proprietary end-effector mounted on a multi-axis robotic arm. This system simultaneously deposits a continuous dry fiber—such as carbon, glass, or aramid—and impregnates it with a tailorable, snap-curing thermoset resin. The material is instantly cured with a focused ultraviolet light source as it is extruded, eliminating the need for costly tooling and post-processing. This mold-less approach not only slashes lead times and production costs but also unlocks unprecedented design freedom.

Engineers can create complex, lightweight geometries with optimized fiber paths that place strength precisely where it is needed, resulting in parts with superior strength-to-weight ratios. The technology also allows for the integration of functional fibers, such as metallic or optical wires, directly into the structure to embed sensing, power transmission, or heating capabilities. The successful application of CF3D with Siemens Energy, which saw a 5x reduction in manufacturing costs and a lead time reduction from over eight months to just three weeks for generator components, underscores the technology's transformative potential.

Fueling the Future of Aerospace and Defense

The timing of this expansion aligns with explosive growth in the advanced materials market. The global aerospace composites market alone was valued at nearly $30 billion in 2024 and is projected to soar to over $96 billion by 2034. This demand is driven by a relentless push in both commercial and military aviation for lighter, stronger, and more fuel-efficient aircraft.

Continuous Composites is strategically positioned to capture a significant share of this market, having cultivated deep relationships within the U.S. defense ecosystem. The company is actively engaged in multiple high-stakes projects with the U.S. Air Force and Army. A multi-year contract with the Air Force Research Laboratory (AFRL) is focused on advancing high-performance materials and benchmarking CF3D for full-scale flight-tested components.

Further collaborations include a recently awarded $1.9 million contract to develop a sophisticated Finite Element Analysis (FEA) tool specifically for CF3D's unique anisotropic materials, which is critical for certifying air- and space-worthy parts. The company also partnered with Lockheed Martin on the WiSDM project to reduce costs for Low-Cost Attritable Aircraft (LCAA) wings and is working with Aurora Flight Sciences, a Boeing subsidiary, on a $2 million U.S. Army contract to develop next-generation fuselage structures for launched effects platforms.

An Ecosystem of Strategic Alliances

Continuous Composites' path to production is fortified by a robust ecosystem of strategic partners spanning materials, software, and industrial automation. A long-standing collaboration with materials science giant Arkema has resulted in a library of N3xtDimension® thermosetting resins specifically formulated for the CF3D process. For precision control, the company's robotic systems are powered by Siemens' Sinumerik CNC platform, ensuring high-accuracy, multi-axis motion.

To accelerate commercial adoption, Continuous Composites has entered into key strategic agreements. A partnership with Saint-Gobain, which included a direct investment, aims to certify CF3D technology for commercial aerospace applications and bring manufacturing into Saint-Gobain's own facilities. More recently, a partnership with the ADDMAN Group will help scale production by making ADDMAN a commercial transition partner, producing test parts and prototypes for critical applications in hypersonics and UAVs.

The value of the company's intellectual property is highlighted by its ongoing efforts to defend it. The U.S. Patent and Trademark Office recently denied multiple petitions filed by competitor Markforged to challenge Continuous Composites' foundational patents, reinforcing the company's proprietary position in the continuous fiber 3D printing space.

Powering Growth in the Pacific Northwest

Beyond its national strategic importance, the expansion represents a significant milestone for the local Coeur d'Alene economy. Founded in the city in 2012, Continuous Composites has maintained a commitment to fostering a high-tech hub in the Pacific Northwest. The move from a cramped downtown office to a spacious industrial facility is a testament to its growth and a promise of future opportunities.

The company plans to expand its current workforce of 30 employees by 15-20% through 2026 and 2027, with an initial focus on hiring engineers followed by support staff. This creates high-paying, high-value tech jobs that allow local talent to build careers in their home region.

This new facility is more than just a larger building; it is a production-ready platform configured for large-format systems and integrated digital workflows. It solidifies Continuous Composites' transition from a promising R&D firm to an industrial-scale manufacturer ready to supply the components that will define the next generation of aerospace and defense technology.