Structural Truss
This project focused on designing and building a lightweight structural truss that could carry competition-level loads while minimizing material usage. I began by defining the target span, expected loading conditions, and safety factor, then sketched multiple truss configurations before selecting a Pratt-style layout for its strength and simplicity. Using Fusion 360, I modeled truss members and joints, iterating on cross sections and connection details to reduce stress concentrations. The final design used laser-cut acrylic gussets and aluminum bar stock, chosen for stiffness-to-weight ratio and easy prototyping in a student lab.
After assembly, I performed load testing by incrementally adding weight at mid-span and recording deflection and failure modes. The truss exceeded the initial load target while maintaining elastic behavior within the design range, but testing showed that joint flexibility had a greater impact on performance than finite element analysis alone suggested. This project reinforced core structural engineering principles, including load paths, tension-compression behavior in truss members, buckling limits, and the importance of connection design. It also highlighted how an iterative path from calculations to CAD, fabrication, and testing builds practical insight into real structures.
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