Additive Molding Carbon-Fiber Truss

Among efficient beams, like I-beams and H-beams, the truss is the ultimate in performance. A truss can carry the same complex loads with less material and less weight. However, trusses have seen limited use in vehicles due to the high assembly cost in existing manufacturing processes. The Arris Composites’ Additive Molding Carbon-Fiber Truss unlocks such previously impossible designs with its large-scale complex truss structure. Similar in size to a steel truss, the Arris composite truss doubles the specific stiffness, a high functional integration, corrosion resistance and weighs less than half of steel.  In a new ground-breaking design and manufacturing process called Additive Molding™, composite fibres are aligned with the stress vectors within a part to optimise the structure’s performance. It combines additive manufacturing, 3D printing and injection moulding to make possible the mass-production of high-strength, light-weight composite parts for a variety of applications and industries. Additive Molding™ unlocks the product design possibilities across a range of industries from aerospace and automotive to sporting and electronic goods. Another key innovation of the manufacturing process is the unprecedented ability called SpecificDesign™ that allows designers to specify and embed different optimal materials into a part. This enables a single part to have the right materials in the right locations, thus optimally solving different functional requirements. A lightweight truss with structurally optimised fibres has important applications in aerospace and automotive design but the ability to embed different functional materials opens new possibilities for vehicle design. A car frame that includes an optimised lightweight truss with wiring and sensors embedded shortens the production line and reduces costs. Smaller consumer items like cell phones will enjoy the same benefits of embedding components such as antennae, wireless charging coils and camera lenses in a single moulded phone housing that’s stronger than metal, half the weight and 100% recyclable. Red Dot Award: Design Concept | Concept | Materials & Surfaces