Arris Additive Molding Carbon-Fiber Truss 2019

Designers: Ethan Escowitz, Arris Composites, Berkeley, California, USA
Manufacturers: Arris Composites, Berkeley, California, USA

Our team designed a first-of-its-kind lattice-type truss made of continuous fiber-reinforced thermoplastic composites (CFRTP) that’s stronger, lighter, and more cost-effective than the I-beam at scale, as well as corrosion-resistant and 100% recyclable.

The I-beam hasn’t seen much innovation since it was developed in 1849. Our newly designed truss solves many problems related to the old fashioned I-beam by invoking the characteristics of efficient structures, materials, and manufacturing processes. Trusses are used in a broad range of applications when there is a requirement to support a load over a span of some distance by what is broadly referred to as a beam. Trusses are designed and evaluated by engineers using beam theory.

Among efficient beams, like I-beams and H-beams, the truss is the ultimate in performance. A truss can carry greater complex loads with the same amount of material or carry the same loads with less material and less weight. This is ideal for any structure that is moved by energy. Manufacturers of wind turbines, rockets, planes, trains, buses, cars, all the way down to scooters have taken notice. Trusses have seen limited use in vehicles due to the high assembly cost and scrap in existing manufacturing processes.

Our team of engineers, 3D printing alums, and manufacturing experts have unlocked previously impossible designs with our large-scale complex truss structure that’s similar in size to a steel truss but with over double the specific stiffness, a high degree of functional integration, corrosion resistance, and less than half the weight.