Abstract: A modular light-weight structural panel is made by stacking in consecutive alternation a number of long, narrow foam plastic filler elements with a number of substantially flat lattice structures. The sub-assembly is laterally compressed to cause each of the lattice structures to be pressed into and partially embedded in mutually abutting surfaces of adjacent ones of the filler elements. While in such compressed condition cross members are welded to side portions of the lattice structures that protrude beyond the filler element surfaces to thereby hold the assembly in its pressed condition with the lattice structures embedded in the filler elements and surfaces of adjacent filler elements in close face-to-face contact with one another.

Abstract: A plurality of wire trusses is employed in a three-dimensional wire matrix having a foam core to provide a light-weight structural building panel. Each truss, comprised of a sinuously bent strut wire having its apices welded to lateral runner wires, is formed by a continuous bending and wire processing apparatus which simultaneously withdraws three wires from wire supplies, sinuously bends the strut wire, assembles the bent strut wire with the runner wires, welds the joints therebetween, and severs desired lengths of completed truss sections. Several wires are fed to the bending station at different speeds and intermittently via three individually automatically controlled wire storage loops. The arrangement is such that even with the several different wire feed rates, all three wires are pulled from wire supply rolls by a single motor and all three are driven to the truss fabrication station by a single motor.