Abstract: Ultra-efficient composite truss structures and methods for manufacturing the same using low cost and high throughput winding processes are presented. The present disclosure describes combining the high structural efficiency of truss structures with the excellent mechanical properties of composite materials using processes that mitigate the high manufacturing costs typical of composite materials. The present disclosure further describes creating the members of the truss structure through continuous winding of either thermoset or thermoplastic matrix, fiber reinforced composite members around a central mandrel. The longitudinal chord members of the truss are held in position by the mandrel, and the web members are wrapped under the chord members, over them, or both. The web members are bonded to the chord members during manufacture to produce a single consolidated truss structure.

Abstract: Ultra-efficient composite truss structures and methods for manufacturing the same using low cost and high throughput winding processes are presented. The present disclosure describes combining the high structural efficiency of truss structures with the excellent mechanical properties of composite materials using processes that mitigate the high manufacturing costs typical of composite materials. The present disclosure further describes creating the members of the truss structure through continuous winding of either thermoset or thermoplastic matrix, fiber reinforced composite members around a central mandrel. The longitudinal chord members of the truss are held in position by the mandrel, and the web members are wrapped under the chord members, over them, or both. The web members are bonded to the chord members during manufacture to produce a single consolidated truss structure.