Defense

CCM drives the development of advanced composite solutions for mission-critical defense applications. Innovations in multifunctional materials, processing science, sensing and control, and mechanics & design support protection, vehicle systems, and defense infrastructure for DoD, NASA and DOE, while enabling scalable manufacturing, lifecycle-aware solutions, and integration across TRL/MRL levels 1–9.

Capabilities

TuFF Programs
Development of Tailorable Universal Feedstock for Forming composites with metal-like formability, closed-loop recycling, and scalable production.
Pilot-Scale Manufacturing
Production of zero-waste, high fiber-volume (60%) feedstock with low void content (<1%) for complex, high-performance components.
Additive Manufacturing
High-temperature polymer additive manufacturing with predictive modeling and rapid fabrication for unmanned vehicles.
Sensing & Control Innovations
Real-time defect detection, cure monitoring, and automated process control for reliable manufacturing.
Soldier Protective Materials & Armor Systems
Multi-scale materials characterization and modeling from atoms to applications for extreme dynamic loading and manufacturing.
Vehicle Applications with TARDEC and Industry
Composite spaceframes, HMMWV/HEMTT cabs, and high-performance chassis components.
NASA Space Suit Applications
Durable, flexible, and resilient materials for extreme environments.
ULI eVTOL Applications
Lightweight, scalable composite architectures for urban air mobility.

Future Aspirations

Rapid, Scalable Composite Manufacturing – Reduce production costs and cycle times for lightweight, high-performance components.
Smart & Multifunctional Defense Materials – Develop composites with self-healing, impact-sensing, or energy-dissipation capabilities.
Circular & Sustainable Defense Solutions – Employ fiber-agnostic, fully recyclable feedstocks for lifecycle-aware manufacturing.
Digitalization & Virtual Validation – Apply virtual manufacturing, AI-assisted modeling, and process simulation to accelerate integration of new composite parts.

Why CCM for Defense?

Institutional Recognition – Multiple DoD and NSF Centers of Excellence; robust DoD funding portfolio.
Full-Spectrum Expertise – Advanced chemistry, design, processing, and testing in state-of-the-art labs.
Industrial & Government Network – Over 350 industry partners and long-term agency engagements.

Humvee driving through sand throwing up a large cloud behind it.

Related Projects

Tailorable Universal Feedstock for Forming (TuFF) Program

Under a $14.9M DARPA cooperative agreement, CCM led the TuFF (Tailorable Universal Feedstock for Forming) program to develop a novel discontinuous fiber composite feedstock that combines metal-like formability, closed-loop recyclability, and aerospace-grade mechanical properties.

Researchers work next to the TuFF manufacturing equipment.

Pilot-Scale TuFF Manufacturing Facility

CCM established a pilot-scale facility for producing zero-waste, fiber-to-part TuFF feedstock with high fiber volume fraction (≈60%) and low void content (

High-Temperature Polymer Additive Manufacturing

In collaboration with ARL, CCM is advancing high-temperature polymer additive manufacturing using the Roboze ARGO 500 system.

Advanced Materials & Intelligent Processing Center (AMIPC)

The Center of Excellence established by ONR at CCM has advanced 3D modeling and optimization capabilities for liquid molding processes across multiple length scales.

Materials for Extreme Dynamic Environments (MEDE)

Through ARL’s MEDE and iCREATE programs, CCM developed a Materials by Design approach for new materials (resins, fibers and interphases) optimized for increased energy absorption and damage tolerance under extreme dynamic loading.

Composites Research and Engineering Technology (iCREATE)

iCREATE developed a broad range of composites technologies for ARL and the industry supply chain.

Researcher wears a prototype military ballistic vest.

Soldier Protective Materials System

In collaboration with ARL/RDECOM and the University of Pittsburgh, CCM has established fundamental understanding of processing-microstructure-performance relationships for improving performance of ultrahigh molecular weight polyethylene fibers and sheets.