Ultra-efficient wound composite truss structures

This paper presents the design, analysis, manufacturing, experimental testing, and multiobjective optimization of a new family of ultra-efficient composite truss structures. The continuously wound truss concept introduced here is a versatile, low cost and scalable method of manufacturing truss structures based on a simple winding process. A prototype truss configuration is shown and experimentally characterized under torsion and three point bending loads. A large deformation implementation of the direct stiffness method is shown to provide good prediction of the stiffness properties of the prototype truss. This model is extended to include strength prediction with multiple failure modes. The design space achievable with these truss structures is then explored through multiobjective optimization using the NSGA II genetic algorithm. These continuously wound truss structures have the potential to provide between one and two orders of magnitude increase in structural efficiency compared to existing carbon fiber composite tubes.