Masonite Truss Bridge

Designed and fabricated a lightweight laser-cut truss bridge using plate-truss geometry, tab-slot assembly, and structural analysis to maximize load capacity relative to weight.

Project Breakdown

  • Built a Pratt truss bridge from scratch for ENGN 0040: Principles of Statics and Dynamics at Brown University
  • Modeled each structural member individually in Autodesk Inventor, then ran frame analysis to verify load paths and member forces before cutting
  • Iterated through 4+ design versions, refining joint geometry, tab-slot connections, and member proportions to improve both strength and weight efficiency
  • Laser cut all pieces from masonite sheet stock, assembling them into a completed bridge weighing approximately 0.9 kg
  • Bridge was destructively load-tested and held over 220 lbs, achieving a high structural efficiency ratio relative to its own weight

Technical Stack

  • Autodesk Inventor (3D Modeling)
  • Frame Analysis (FEA)
  • Laser Cutting (Masonite)
  • Truss / Structural Design
  • Tab-Slot Joinery
  • Iterative Prototyping
  • Statics & Free Body Diagrams
  • Load Testing

References

  • Lab Report (coming soon)
Truss bridge photo

Completed Pratt truss bridge — front angle view showing chord and diagonal member layout