Continuously extruded wrapped tow reinforced truss beams

Recent advancements in composite truss structures have achieved high structural efficiency by combining truss geometries and composite materials within scalable manufacturing processes. Filament winding-based approaches, such as the Wrapped Tow Reinforced (WrapToR) truss process, allow for simpler machine design compared to braiding or pultrusion but face limitations as production rates and truss beam lengths increase. We herein introduce WrapToR Trusstrusion, a manufacturing concept using coaxial winding heads to wrap multiple pre-wetted tows around continuously fed chord members, forming a complete wound truss structure in one pass. This eliminates the need for reciprocating motion and fixed mandrel lengths of conventional winding machines. We present the WrapToR Trusstrusion concept, the first prototype machine setup, and the numerical analysis and mechanical characterisation of produced specimens, aiming to assess the quality of the produced trusses. This innovative machine concept progresses towards high-throughput, continuous production of mechanically superior WrapToR truss beams while trading off process and geometry versatility for standardisation and production rate.