Additively manufactured prefabricated structural elements

Abstract

A system of prefabricated structural elements, having a set of parallel first trusses, wherein each first truss extends between a proximal end and a distal end, having a top edge having a plurality of first notches positioned between the proximal end to the distal end, a bottom edge spaced from the top edge and a plurality of internal members, a set of parallel second trusses positioned perpendicular to the first trusses, wherein each second truss extends between a proximal end and a distal end, having a top edge, a bottom edge having a plurality of complementary notches formed therein, a plurality of internal members wherein each one of the plurality of first notches is shaped to receive and engage with a respective corresponding one of the plurality of complementary notches thereby forming an interlocking web.

Description

MTV-25225ADDITIVELY MANUFACTURED PREFABRICATED STRUCTURAL ELEMENTSCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application is an International Application filed under the Patent Cooperation Treaty, which claims the benefit of priority to U.S. Provisional Application No. 63 / 708,679, filed October 17, 2024; the entire contents of which are incorporated by reference.BACKGROUND OF THE DISLCOSED SUBJECT MATTER

[0002] A truss is a structural framework composed of triangular units connected at joints, typically designed to support loads and span distances. The geometric rigidity of triangles makes trusses stable and efficient in bearing loads. Current uses of trusses include building construction, bridges, towers, and masts. Most trusses are made from wood (mainly for roof or floor construction) or metal (steel or aluminum for civil structures such as bridges and towers).SUMMARY OF THE DISLCOSED SUBJECT MATTER

[0003] The purpose and advantages of the disclosed subject matter will be set forth in and apparent from the description that follows, and as will be learned by practice of the disclosed subject matter. Additional advantages of the disclosed subject matter will be realized and attained by the methods and systems particularly pointed out in the written description and claims hereof, as well as from the appended drawings.

[0004] This summary is provided to introduce a selection of concepts in a simplified form, that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the claimed subject matter. Nor is this summary intended to be used to limit the scope of the claimed subject matter.1FH13073853.5MTV-25225

[0005] To achieve these and other advantages and in accordance with the purpose of the disclosed subject matter, as embodied and broadly described, the disclosed subject matter includes a system of prefabricated structural elements, the system having: a set of first trusses positioned parallel to one another and a first axis, wherein each first truss extends between a first proximal end and a first distal end, and includes a top edge having a plurality of first notches positioned between the first proximal end to the first distal end; a bottom edge spaced from the top edge; and a plurality of internal members extending from the top edge to the bottom edge to form a planar rigid frame; a set of second trusses positioned parallel to one another and perpendicular to the set of first trusses, wherein each second truss extends between a second proximal end and a second distal end, and includes a top edge; a bottom edge having a plurality of complementary notches formed therein; a plurality of internal members extending from the top edge to the bottom edge to form a planar rigid frame; wherein each one of the plurality of first notches is shaped to receive and engage with a respective corresponding one of the plurality of complementary notches thereby forming an interlocking web.

[0006] In some embodiments, the first trusses and the second trusses are additively manufactured.

[0007] In some embodiments, the first trusses and the second trusses are formed from a plastic material or a fiber-reinforced plastic material.

[0008] In some embodiments, the first trusses and the second trusses are formed from a composite material.

[0009] In some embodiments, the first trusses and the second trusses include acrylonitrile butadiene styrene (ABS) having carbon fiber filaments embedded therein.

[0010] In some embodiments, the first trusses and second trusses are formed from a metal material.2FH13073853.5MTV-25225

[0011] In some embodiments, the first trusses and the second trusses are formed from a recycled material.

[0012] In some embodiments, the top edges of the first trusses and the second trusses are positioned in a plane to form the interlocking web having a planar top surface.

[0013] In some embodiments, each first proximal end is positioned at a first elevation and each first distal end is positioned at a second elevation, wherein the second elevation is below the first elevation, and wherein each second truss is regularly positioned between the first elevation and the second elevation, thereby forming a ramped interlocking web.

[0014] In some embodiments, the plurality of second trusses are oriented at an oblique angle relative to the plurality of first trusses.

[0015] The herein disclosed subject matter is also directed to a system of prefabricated structural elements, the system having a plurality of stringers extending parallel to one another, each stringer having: an inclined top chord extending between a first proximal end and a first distal end, the top chord defining a plurality of stepped surfaces descending from the first proximal end to the first distal end, a plurality of first notches disposed along the plurality of stepped surfaces; an inclined bottom chord spaced from the inclined top chord and extending between the first proximal end and the first distal end; a plurality of internal members extending between the top chord and the bottom chord forming a trussed joist frame; a plurality of treads positioned along the plurality of stringers, each tread extending perpendicular to the plurality of stringers, each tread including: a top edge extending between a second proximal end and a second distal end; a bottom edge spaced from the top edge; a plurality of internal members extending between the top edge and the bottom edge forming a truss; a plurality of complementary notches disposed along the bottom edge; and wherein each one of the plurality of first notches is shaped to receive and engage with a respective corresponding one of the plurality of complementary notches thereby forming an interlocking3FH13073853.5MTV-25225 web wherein respective top edges of the stringers are aligned with the plurality of stepped surfaces along the top chord.

[0016] In some embodiments, each stepped surface includes two complementary notches.

[0017] In some embodiments, a first complementary notch is disposed at a proximal edge of a respective stepped surface, and a second complementary notch is disposed at a distal edge of the respective stepped surface.

[0018] In some embodiments, each of the treads is oriented at an oblique angle relative to the plurality of joist frames.

[0019] In some embodiments, each of the stringers and each of the treads are additively manufactured.

[0020] In some embodiments, each of the stringers and each of the treads are formed from a plastic material or a fiber-reinforced plastic material.

[0021] In some embodiments, each of the stringers and each of the treads are formed from a composite material.

[0022] In some embodiments, each of the stringers and the treads includes acrylonitrile butadiene styrene (ABS) having carbon fiber filaments embedded therein.

[0023] In some embodiments, each of the stringers and each of the treads are formed from a metal material.

[0024] In some embodiments, each of the stringers and the treads are formed from a recycled material.

[0025] The disclosed subject matter is also directed to a system of prefabricated structural elements, the system having: at least one first planar truss having: a first perimeter delimiting the at least one first planar truss; at least one internal member spanning the first perimeter; wherein the at least one first planar truss is additively manufactured.4FH13073853.5MTV-25225

[0026] In some embodiments, the at least one first planar truss comprises a geometric feature configured to receive and matingly engage with at least one other structural component.

[0027] In some embodiments, the at least one structural component comprises at least one second planar truss.

[0028] In some embodiments, the at least one second planar truss comprises: a second perimeter delimiting the at least one second planar truss; and at least one internal member spanning the second perimeter; wherein the at least one second planar truss is additively manufactured.

[0029] In some embodiments, the at least one second planar truss comprises a geometric feature configured to receive and matingly engage with the at least one first planar truss or the structural component.

[0030] In some embodiments, further including a plurality of second planar trusses, each comprising at least one geometric feature configured to matingly engage with the at least one other of the second planar trusses.

[0031] In some embodiments, the geometric feature comprises at least one notch formed in the first perimeter or the second perimeter.

[0032] In some embodiments, the geometric feature comprises a shoulder.

[0033] In some embodiments, the geometric feature comprises a slotted feature.

[0034] In some embodiments, the at least one first planar truss and the at least one second planar truss interlock to form a structural web.

[0035] In some embodiments, the first perimeter and the second perimeter are substantially rectilinear.5FH13073853.5MTV-25225

[0036] In some embodiments, the at least one planar truss comprises a protrusion, and the at least one second planar truss comprises a slotted feature, and the protrusion is configured to matingly engage with the slotted feature.

[0037] In some embodiments, the first perimeter and the second perimeter are substantially triangular.

[0038] In some embodiments, the first planar truss or the at least one second planar truss is formed as one selected from the group of: a kingpost, a fink, double fink, dual pitch, inverted, queenpost, modified queenpost, gambrel, piggyback, hip, Polynesian, studio, howe, double howe, scissors, attic, cathedral, fan, monopitch, bowstring, flat, sloping flat, cambered or stub roof joist.

[0039] In some embodiments, the first planar truss and the at least one second planar truss are coupled at an angle.

[0040] In some embodiments, at least a portion of the at least one first planar truss and the at least one second truss are formed from one selected from a group of: a plastic material, a fiber-reinforced plastic material, a composite material, or a metal material.

[0041] In some embodiments, the at least one first truss and the at least one second truss comprise acrylonitrile butadiene styrene (ABS) having carbon fiber filaments embedded therein.

[0042] In some embodiments, the at least one first truss and the at least one second truss comprise recycled polyethylene terephthalate (rPET).

[0043] The disclosed subject matter is also directed a system of prefabricated structural elements, the system including a first hanger joist and a second hanger joist spaced apart and extending parallel to one another, each having a top chord spaced from a bottom chord with a plurality of internal members extending therebetween, wherein the plurality of internal members form a plurality of opposite and opposing slots; at least one planar joist6FH13073853.5MTV-25225 extending from a proximal end to a distal end, the at least one planar joist having a top chord spaced from a bottom chord with a plurality of internal members extending between the top chord to the bottom chord, wherein the at least one planar joist extends perpendicularly between the first and the second hanger joists, and is configured to engage with one of the plurality of slots of the first hanger joist at the proximal end and engage with one of the plurality of slots of the second hanger joist at the distal end to form an interlocked web structure.

[0044] In some embodiments, the at least one planar joist includes a plurality of reinforced nodes disposed at points where the plurality of internal members contact the bottom chord.

[0045] In some embodiments, the system includes a plurality of parallel planar joists spaced from one another, each of the plurality of planar joists configured to engage with a respective one of the plurality of slots of the first and the second hanger joists at respective distal and proximal ends.

[0046] In some embodiments, the top chords of the plurality of planar joists and the first and the second hanger joists are coplanar.

[0047] In some embodiments, a first portion of the plurality of planar joists has a first thickness, and a second portion of the plurality of planar joists has a second thickness.

[0048] In some embodiments, the system further includes at least one pile configured to engage with the bottom chord of at least one of the first or the second hanger joists.

[0049] In some embodiments, the at least one pile includes an upper forked end, forming a central notch between opposite upwardly extending protrusions, the central notch configured to receive the bottom chord of the first or the second hanger joist.

[0050] In some embodiments, a first pair of piles is configured to receive the first hanger joist and a second pair of piles is configured to receive the second hanger joist.7FH13073853.5MTV-25225

[0051] In some embodiments, the system further includes a plurality of end side wall studs, each end side wall stud having an elongate body having a lower shoulder end opposite an upper forked end.

[0052] In some embodiments, each of the plurality of end side wall studs is configured to engage with the top chord of at least one planar joists at the lower shoulder end and configured to engage with a roof joist at the upper forked end.

[0053] In some embodiments, the system further includes a plurality of hanger side wall studs, each hanger side wall stud having an elongate body having a lower shoulder end opposite an upper shoulder end.

[0054] In some embodiments, each of the plurality of hanger side wall studs is configured to engage with the top chord of at least one hanger joist and at least one planar joist at the lower shoulder end and configured to engage with a roof joist at the upper shoulder end.

[0055] In some embodiments, the system includes a plurality of outer corner studs, wherein each of the outer corner studs has an elongate body with a lower shoulder end opposite a rectilinear end.

[0056] In some embodiments, each of the outer corner studs is configured to engage with a terminal one of the plurality of planar joists at the lower shoulder end and configured to engage with a roof joist at the rectilinear end.

[0057] In some embodiments, the system includes a plurality of hanger side corner studs, wherein each of the hanger side corner studs has an elongate body with a lower shoulder end opposite an upper rectilinear end.

[0058] In some embodiments, each of the hanger side comer studs is configured to engage with at least one hanger joist and at least one planar joist at the lower shoulder end, and to engage with a roof joist at the upper rectilinear end.8FH13073853.5MTV-25225

[0059] In some embodiments, at least a portion of the prefabricated structural elements are additively manufactured.

[0060] In some embodiments, the prefabricated structural elements are formed from a recycled polyethylene terephthalate (rPET).

[0061] In some embodiments, at least a portion of the prefabricated structural elements are formed from at least one of a plastic material, a fiber-reinforced plastic material, a composite material, or a metal material.

[0062] Both the foregoing summary and the following detailed description provide examples and are explanatory only. Accordingly, the foregoing summary and the following detailed description should not be considered to be restrictive. Further, features or variations may be provided in addition to those set forth herein. For example, embodiments may be directed to various feature combinations and sub-combinations described in the detailed description. It is to be understood that both the foregoing general description and the following detailed description are exemplary and are intended to provide further explanation of the disclosed subject matter claimed.BRIEF DESCRIPTION OF THE DRAWINGS

[0063] A detailed description of various aspects, features, and embodiments of the subject matter described herein is provided with reference to the accompanying drawings, which are briefly described below. The drawings are illustrative and are not necessarily drawn to scale, with some components and features being exaggerated for clarity. The drawings illustrate various aspects and features of the present subject matter and may illustrate one or more embodiment(s) or example(s) of the present subject matter in whole or in part.

[0064] FIG. 1 A is a schematic diagram of a truss with exemplary notches to allow for interlocking in accordance with an aspect of the disclosed subject matter.9FH13073853.5MTV-25225

[0065] FIG. IB is a schematic diagram of a truss with exemplary complementary notches to allow for interlocking in accordance with an aspect of the disclosed subject matter.

[0066] FIG. 2A is an yz-plane view of a webbed floor joint system showing the interlocking of a plurality of second trusses with a first truss in accordance with an aspect of the disclosed subject matter.

[0067] FIG. 2B is a xz-plane view of a webbed floor joint system showing the interlocking of a plurality of first trusses with a second truss in accordance with an aspect of the disclosed subject matter.

[0068] FIG. 2C is a dimetric exploded view of a floor joint system formed by a set of first trusses and a set of second trusses in accordance with an aspect of the disclosed subject matter.

[0069] FIG. 2D is a dimetric view of an assembled floor joist system in accordance with an aspect of the disclosed subject matter.

[0070] FIG. 2E is a perspective view of an endcap in accordance with an aspect of the disclosed subject matter.

[0071] FIG. 2F is a perspective view of a pile in accordance with an aspect of the disclosed subject matter.

[0072] FIG. 2G is a perspective view of an endcap engaged with two piles in accordance with an aspect of the disclosed subject matter.

[0073] FIG. 2H is a perspective view of a flooring system utilizing an endcap or hanger joist, piles and planar joists in accordance with an aspect of the disclosed subject matter.

[0074] FIG. 21 is a planform view of an arched joist in accordance with an aspect of the disclosed subject matter.10FH13073853.5MTV-25225

[0075] FIG. 3 is a trimetric view of an assembled ramp joist system in accordance with the disclosed subject matter.

[0076] FIG. 4A is an exploded view of a ramp joist system in accordance with an aspect of the disclosed subject matter.

[0077] FIG. 4B is a side view of ramp joist tread placement onto the stringers in accordance with an aspect of the disclosed subject matter.

[0078] FIG. 5 is a trimetric view of an assembled stair joist system in accordance with an aspect of the disclosed subject matter.

[0079] FIG. 6A is a trimetric exploded view of a stair joist system in accordance with an aspect of the disclosed subject matter.

[0080] FIG. 6B is a side view of stair joist tread placement onto stringers in accordance with an aspect of the disclosed subject matter.

[0081] FIG. 7A depicts schematic views of exemplary interlocking additively manufactured roof truss structures in accordance with an aspect of the disclosed subject matter.

[0082] FIG. 7B is a schematic representation of a plurality of roof joists in accordance with an aspect of the disclosed subject matter.

[0083] FIG. 8A is a schematic representation of roof truss structure configurations.

[0084] FIG. 8B is a schematic representation of roof truss structure configurations.

[0085] FIG. 8C is a schematic representation of roof truss structure configurations.

[0086] FIG. 8D is a schematic representation of roof truss structure configurations.

[0087] FIG. 8E is a schematic representation of roof truss structure configurations.

[0088] FIG. 8F is a schematic representation of roof truss structure configurations.

[0089] FIG. 9A is an exemplary embodiment of prefabricated structural truss in accordance with an aspect of the disclosed subject matter.11FH13073853.5MTV-25225

[0090] FIG. 9B is an exemplary embodiment of prefabricated structural truss in accordance with an aspect of the disclosed subject matter.

[0091] FIG. 9C is an exemplary embodiment of prefabricated structural truss in accordance with an aspect of the disclosed subject matter.

[0092] FIG. 9D is an exemplary embodiment of prefabricated structural truss in accordance with an aspect of the disclosed subject matter.

[0093] FIG. 10A is schematic planform view of a hanger joist in accordance with an aspect of the disclosed subject matter.

[0094] FIG. 10B is schematic planform view of a planar joist in accordance with an aspect of the disclosed subject matter.

[0095] FIG. 11 A is a planform view of a planar end side wall stud in accordance with an aspect of the disclosed subject matter.

[0096] FIG. 1 IB is a schematic representation of a plurality of end side wall studs coupled to floor joists (righthand side) and a detail cross-sectional view of a joint formed between floor joists and the end sidewall stud (lefthand side).

[0097] FIG. 11C is a schematic representation of a plurality of end side wall studs coupled to a roof joist (righthand side) and a detail cross-sectional view of a joint formed between roof joist and the end sidewall stud (lefthand side).

[0098] FIG. 12A is a schematic planform view and side view of a hanger side wall stud in accordance with an aspect of the disclosed subject matter.

[0099] FIG. 12B is a schematic planform view and side view of a hanger side corner stud in accordance with an aspect of the disclosed subject matter.

[0100] FIG. 12C is a schematic planform view and side view of an outer corner stud in accordance with an aspect of the disclosed subject matter.12FH13073853.5MTV-25225

[0101] FIG. 12D is a schematic side view of a plurality of hanger side wall studs coupled to successive floor joists and hanger joists (lefthand side) and a detail view of the joint (righthand side) in accordance with an aspect of the disclosed subject matter.

[0102] FIG. 12E is a schematic cross-section view of a corner joint formed by hanger joist, planar joists, outer corner stud and hanger side corner stud (center) and detail views of the outer corner stud joint (lefthand side) and hanger side corner stud joint (righthand side) according to aspects of the disclosed subject matter.

[0103] FIG. 12F is a schematic cross section view of a joint formed by a roof joist and the upper ends of the outer corner stud and hanger side corner stud (center) and detail views of the outer corner stud (lefthand side) and hanger side corner stud (righthand side).

[0104] FIG. 12G is a schematic cross-section view of a joint formed between a roof joist and an end side wall stud (righthand side) and a side view of the joint (lefthand side) in accordance with an aspect of the disclosed subject matter.

[0105] FIG. 13 is a depiction of a structure constructed using prefabricated structural elements in accordance with an aspect of the disclosed subject matter.

[0106] FIG. 14 is a schematic diagram of a tool path for fabrication of a prefabricated structural element in accordance with an aspect of the disclosed subject matter.

[0107] The accompanying drawings, which are incorporated in and constitute part of this specification, are included to illustrate and provide a further understanding of the method and system of the disclosed subject matter. Together with the description, the drawings serve to explain the principles of the disclosed subject matter.DETAILED DESCRIPTION

[0108] As a preliminary matter, it will readily be understood by one having ordinary skill in the relevant art that the present disclosure has broad utility and application. As should be understood, any embodiment may incorporate only one or a plurality of the above-13FH13073853.5MTV-25225 disclosed aspects of the disclosure and may further incorporate only one or a plurality of the above-disclosed features.

[0109] Accordingly, while embodiments are described herein in detail in relation to one or more embodiments, it is to be understood that this disclosure is illustrative and exemplary of the present disclosure, and are made merely for the purposes of providing a full and enabling disclosure.

[0110] Thus, for example, any sequence(s) and / or temporal order of steps of various processes or methods that are described herein are illustrative and not restrictive.Accordingly, although steps of various processes or methods may be shown and described as being in a sequence or temporal order, the steps of any such processes or methods are not limited to being carried out in any particular sequence or order, absent an indication otherwise. Indeed, the steps in such processes or methods generally may be carried out in various different sequences and orders while still falling within the scope of the present invention.

[0111] Additionally, it is important to note that each term used herein refers to that which an ordinary artisan would understand such term to mean based on the contextual use of such term herein. To the extent that the meaning of a term used herein — as understood by the ordinary artisan based on the contextual use of such term — differs in any way from any particular dictionary definition of such term, it is intended that the meaning of the term as understood by the ordinary artisan should prevail.

[0112] The following detailed description refers to the accompanying drawings.Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements. While many embodiments of the disclosure may be described, modifications, adaptations, and other implementations are possible. For example, substitutions, additions, or modifications may be made to the elements14FH13073853.5MTV-25225 illustrated in the drawings, and the methods described herein may be modified by substituting, reordering, or adding stages to the disclosed methods. Accordingly, the following detailed description does not limit the disclosure.

[0113] The disclosed subject matter, in an aspect, concerns methods for manufacturing and using structural trusses. A truss is a structural framework composed of triangular units connected at joints, typically designed to support loads and span distances. The geometric rigidity of triangles makes trusses stable and efficient in bearing loads. Current uses of trusses include building construction, bridges, towers, and masts. The vast majority of trusses are made from wood (mainly for roof or floor construction) or metal (steel or aluminum for civil structures such as bridges and towers).

[0114] An aspect of the disclosed subject matter may involve the use of large-scale additive manufacturing to create novel truss geometries that create lightweight, low-cost structure from plastic and plastic composites. The use of this process takes advantage of not only the geometric flexibility of the manufacturing, but also the ability to use recycled plastic.

[0115] In various embodiments, the prefabricated structural elements described herein may be additively manufactured using recycled polyethylene terephthalate (rPET) or rPET infused with glass fibers (rPET-glass fiber) material, such as rPET-GF30 composite material. The rPET may be recycled from PET bottles and packaging. In various embodiments, the prefabricated structural elements may be formed from Airtech DALTHRAM-100GF, which may contain recycled copolyester with 30% glass fiber reinforcement, having a tensile modulus (longitudinal to print direction) of 6.6 gigapascals (GPa), tensile modulus (transverse to print direction) of 3.7 GPa, tensile strength (longitudinal) of 79.3 GPa and tensile strength (transverse) of 25.9 GPa. Any material described herein may be selected and optimized based on manufacturing equipment utilized, such as a Cincinnati BAAM 603, CEAD, Thermwood 1540, Ingersoll MasterPrint 3x, among or other large scale additive15FH13073853.5MTV-25225 manufacturing (LSAM) equipment. LSAM equipment may include a variety of throughputs, such as 50 pounds per hour (lb. / hr) to 1000 lb. / hr, including various nozzles sizes, screw size, and extruder arrangements, such as anti-clog tappers, gravity feed hoppers, and cold jets to prevent uneven pellet feeding.

[0116] Any truss or prefabricated structural element, such as joists, studs, piles, or the like may be printed using additive manufacturing equipment in one print process, wherein nodes of intersecting or contacting members are bonded together where relatively hot polymer flows together during printing to form a bond. LSAM may be employed. Further, any truss or prefabricated structural element described herein may be described as planar, such as being formed from a generally 2D shape extruded to provide required thickness, however, angled components may be printed utilizing additive manufacturing methods disclosed herein.

[0117] Referring now to FIG. 1 A, a side view of a first truss 104 is shown. First truss 104 may include a top edge 105 extending between a first proximal end and a first distal end. Top edge 105 may be substantially straight and parallel to the y-axis as shown in FIG. 1 A. First truss 104 may include a bottom edge 106 spaced from the top edge 105 and substantially parallel thereto. First truss 104 may include any number of internal members 107 extending between the top edge 105 and the bottom edge 106 to form a plurality of triangular sections, or trusses. In various embodiments, internal members 107 may extend between only top edge 105 and bottom edge 106. In various embodiments, some internal members 107 may extend between top edge 105 and another internal member 107. In various embodiments, some internal members 107 may extend between bottom edge 106 and another internal member 107. In various embodiments, first truss 104 may include any number of internal members 107 configured to span from the top edge 105 to bottom edge 106 and from each of the top edge 105 and bottom edge 106 to any number of other internal members 107.16FH13073853.5MTV-25225First truss 104 may include any number of internal members 107 spanning from the top edge 105 to the bottom edge 106. The internal members 107 may be arranged in tandem with the top edge 105 and bottom edge 106, to form any number of triangular sections, or trusses. The internal members 107 may be arranged at any angle relative to the top edge 105 and the bottom edge 106 such that the triangular sections take on various shapes themselves.

[0118] With continued reference to FIG. 1 A, first truss 104 may be formed such that it substantially lies in a single plane, such that each edge and internal member may extend within a single plane, and the first truss 104 will have flat surfaces on its two lateral sides (z.e., in the yz plane of FIG. 1 A). First truss 104 is shown with a generally rectilinear shape, in an exemplary embodiment, however, first truss 104 may be formed having a different shape, having triangular sections formed therebetween, such as other polygons. In various embodiments, first truss 104 may be formed with a triangular outer perimeter or a substantially triangular perimeter. In various embodiments, first truss 104 may be formed with a substantially trapezoidal outer perimeter.

[0119] With continued reference to FIG. 1 A, first truss 104 may be configured to be interlocked or be formed with features which are configured to interlock with one or more other components, such as other first trusses 104 or the like. In various embodiments, truss 104 may include notches 108 configured to constrain first truss 104 relative to another truss interlocked therewith. In various embodiments, notches 108 may be disposed along the topmost edge 105 of first truss 104. In various embodiments, notches 108 may be disposed at points on lateral edges of first truss 104, or along a bottom edge 106 of first truss 104. In various embodiments, notches 108 may be disposed on one or more of the intervening members 107 of first truss 104. For example, and without limitation, notches 108 may be added to the structure for perpendicular trusses (204, to be described below) to slot into, and act as kinematic constraints in the y-direction, for example. In various embodiments, notch17FH13073853.5MTV-25225108 may be formed during the additive manufacturing process. In various embodiments, notch 108 may be formed from a downstream manufacturing process, such as machining after first truss 104 is printed. In various embodiments, notch 108 may be formed as a rectilinear recess in the top edge 105 of the generally planar first truss 104. In various embodiments, notch 108 may include a differing geometry, such as a ‘v’ shaped cutout or ‘v’ shaped recess in the first truss 104.

[0120] First truss 104 may include a plurality of first notches 108. First notches 108 may be formed in the bottom edge 106. Notches 108 may be formed as recesses between adjacent internal members 107 such that notches 108 include a ‘bottom side’ that is proximate the bottom edge 106. One of skill in the art would appreciate that the shape of notches 108 in conjunction with the shape of complementary notches 208, when mated together, will define the structural relationship of the first truss 104 and the second truss 204. That is to say, that the shape of notches 108 may be adjusted to form web structures of optimal overall shape and load-bearing capability.

[0121] In various embodiments, notch 108 may include features that retain another truss therein, such as bosses, snaps, or the like. In various embodiments, notch 108 may be configured to temporarily or permanently retain another truss matingly therein, such as compliant features configured to snap into place upon coupling of distinct trusses together. In various embodiments, notch 108 may have an adhesive applied prior to coupling distinct trusses. In various embodiments, a downstream manufacturing step may be applied to the notch 108 to retain a distinct truss therein, such as mechanical fastening or the like.

[0122] In various embodiments, first truss 104 may be formed through large scale additive manufacturing, such as 3D printing, among others. In various embodiments, first truss 104, and any truss as described herein, may be formed from plastic, fiber-reinforced plastic, or a similar material, such as recycled plastic. Plastic may be used in truss18FH13073853.5MTV-25225 construction offers several key benefits over wood and metal construction. For example, and without limitation, plastic trusses are highly resistant to corrosion, making them ideal for environments with moisture or chemicals, and they require significantly less maintenance, as it would not rust, rot or require painting. For example, and without limitation, plastic trusses may be lightweight and therefore simplify transportation, handling, and installation, reducing the load on building foundations. For example, and without limitation, plastic trusses may be beneficial because of plastic material’s moldability, which may allow for innovative design possibilities, and its thermal insulative properties may contribute to energy efficiency. For example, and without limitation, many plastics are recyclable and can be produced more resource-efficiently compared to traditional materials.

[0123] In various embodiments, first truss 104 may be formed from a composite material or a polymer. In various embodiments, first truss 104 may be formed at least in part by acrylonitrile butadiene styrene (ABS) and / or ABS with carbon fiber filaments embedded therein (ABS CF). In various embodiments, first truss 104 may be formed at least in part by metal or a metal alloy.

[0124] Referring now to FIG. IB, a second truss 204 is shown in a side planar view. Second truss 204 may be formed from a top edge 205 and a bottom edge 206 spaced therefrom. Top edge 205 and bottom edge 206 may be substantially parallel and extend between a proximal end and a distal end. Second truss 204 may include any number of internal members 207 spanning from the top edge 205 to the bottom edge 206. The internal members 207 may be arranged that in tandem with the top edge 205 and bottom edge 206, form any number of triangular sections, or trusses. The internal members 207 may be arranged at any angle relative to the top edge 205 and the bottom edge 206 such that the triangular sections take on various shapes themselves. Second truss 204 may include a plurality of complementary notches 208. Complementary notches 208 may be formed in the19FH13073853.5MTV-25225 bottom edge 206. Complementary notches 208 may be formed as recesses between adjacent internal members 207 such that complementary notches 208 include a ‘bottom side’ that is proximate the top edge 205. One of skill in the art would appreciate that the shape of complementary notches 208 in conjunction with the shape of first notches 108, when mated together, will define the structural relationship of the first truss 104 and the second truss 204. That is to say, that the shape of complementary notch 208 may be adjusted to form web structures of optimal overall shape and load-bearing capability.

[0125] With continued reference to FIG. IB, second truss 204 may be formed such that it substantially lies in a single plane, that is to say that each edge and internal member may extend within a single plane, and the second truss 204 will have flat surfaces on its two lateral sides ( / .<?., in the xz plane of FIG. IB). Second truss 204 is shown with a generally rectilinear shape, in an exemplary embodiment, however, second truss 204 may be formed having a different shape, having triangular sections formed therebetween, such as other polygons. In various embodiments, second truss 204 may be formed with a triangular outer perimeter or a substantially triangular perimeter. In various embodiments, second truss 204 may be formed with a substantially trapezoidal outer perimeter.

[0126] In various embodiments, second truss 204 may be formed through large scale additive manufacturing, such as 3D printing, among others. In various embodiments, second truss 204, and any truss as described herein, may be formed from plastic, fiber-reinforced plastic or a similar material, such as recycled plastic. In various embodiments, second truss 204 may be formed from plastic for any reasons as described above in reference to first truss 104. In various embodiments, second truss 204 may be formed at least in part form a thermally insulating material. In various embodiments, first truss 104 may be formed from a composite material or a polymer. In various embodiments, first truss 104 may be formed at least in part by acrylonitrile butadiene styrene (ABS) and / or ABS with carbon fiber filaments20FH13073853.5MTV-25225 embedded therein (ABS CF). In various embodiments, first truss 104 may be formed at least in part by metal or a metal alloy.

[0127] Referring now to FIG. 2A, a schematic side view of first truss 104 is shown with a plurality of second trusses 204 interlocking therewith, the movement of second trusses 204 is denoted by the arrows. Although a single first truss 104 is shown in FIG. 2A, one of skill in the art would appreciate that a plurality of first trusses 104 substantially parallel to the shown first truss may be positioned regularly behind it, such that a plurality of first trusses 104 and a plurality of second trusses 204 are shown interlocking. Each second truss 204 is shown being positioned over each notch 108. Each notch 108 may be shaped to receive and matingly coupled with a respective corresponding one of the complementary notches 208 (hidden from view by the ends of second trusses 204 in FIG. 2A). The notches 108 may be shaped such that upon mating, the top edge 105 of first truss 104 and top edge 205 of second trusses 204 are aligned, as will be shown in FIG. 2D. Notches 108 may be shaped such that upon mating with complementary notches 208, the plurality of second trusses 204 are constrained in the y-direction. In various embodiments, notches 108 may be formed normally to the plane of first truss 104, such that second trusses 208 are retained in a perpendicular relationship with first truss 104. In various embodiments, notches 108 may be formed in a non-perpendicular manner to the plane of first truss 104, such that the relative angle between first truss 104 and second trusses 204 may be non-perpendicular. For example, and without limitation, second trusses 204 in such an arrangement may be retained at an oblique angle to first truss 104. In various embodiments, second trusses 204 may be retained such that the second trusses 204 may extend non-parallel to the z-axis, for example.

[0128] Referring now to FIG. 2C, a schematic side view of second truss 204 is shown with a plurality of first trusses 104 interlocking therewith, the movement of second truss 204 is denoted by the arrows. Although a single second truss 204 is shown in FIG. 2B, one of21FH13073853.5MTV-25225 skill in the art would appreciate that a plurality of second trusses 204 substantially parallel to the shown second truss may be positioned regularly behind it, such that a plurality of second trusses 204 and a plurality of first trusses 104 are shown interlocking. Second truss 204 is shown being positioned with each complementary notch 208 over each first notch 108 (hidden from view) on the first trusses 104. Each complementary notch 208 may be shaped to receive and matingly fit over a respective corresponding one of the first notches 108 (hidden from view by the ends of first trusses 104 in FIG. 2B).

[0129] The complementary notches 208 may be shaped such that upon mating, the top edge 105 of first truss 104 and a top edge 205 of second trusses 204 are aligned, as will be shown in FIG. 2D. Complementary notches 208 may be shaped such that upon mating with first notches 108, the plurality of first trusses 104 are constrained in the x-direction. In various embodiments, complementary notches 208 may be formed normally to the plane of second truss 204, such that first trusses 104 are retained in a perpendicular relationship with second truss 204. In various embodiments, complementary notches 208 may be formed in a non-perpendicular manner to the plane of second truss 204, such that the relative angle between first truss 104 and second trusses 204 may be non-perpendicular. For example, and without limitation, first trusses 104 in such an arrangement may be retained at an oblique angle to second truss 204. In various embodiments, first trusses 104 may be retained such that the first trusses 104 may extend non-parallel to the z-axis, for example.

[0130] FIG. 2C is a dimetric exploded view of a plurality of first trusses 104 and a plurality of second trusses 204 aligned but not yet assembled to form an interlocking web. The plurality of first trusses 104 are poisoned parallel to one another and aligned extending along the y-axis in this example. Although five first trusses 104 are shown in FIG. 2C, one of skill in the art would appreciate that any number of first trusses 104 of any length may be positioned parallel to one another depending on the application of the interlocking web. Each22FH13073853.5MTV-25225 first truss 104 is shown having a plurality of first notches 108. As shown in FIG. 2C, each first truss 104 is shown having exactly five first notches 108, however any number of first notches 108 can be disposed along each first truss. Further as shown, each notch 108 of first truss 104 is shown at an apex of two internal members 107, however, any placement of notch 108 can be implemented in the prefabricated frame of first truss 104. In various embodiments, the first notches 108 may be spaced regularly or irregularly, / .<?., the spacing between adjacent notches 108 may vary along the length of first truss 104. Further, as shown in FIG. 2C, the top and bottom edges of first truss 104 are aligned along the z-axis, such that the plane of each first truss 104 is normal to the x axis, however, canted first trusses 104 may be implemented depending on the application of the interlocking web.

[0131] With continued reference to FIG. 2C, a plurality of second trusses 204 are shown extending along the x axis and substantially parallel to one another. Although second trusses 204 are shown in FIG. 2C, one of skill in the art would appreciate that any number of second trusses 204 of any length may be positioned parallel to one another depending on the application of the interlocking web. Each second truss 204 is shown having a plurality of complementary notches 208. As shown in FIG. 2C, each second truss 204 is shown having exactly five complementary notches 208, however any number of complementary notches 208 can be disposed along each second truss.

[0132] Further as shown, each complementary notch 208 of second truss 204 is shown at an apex of two internal members 207, however, any placement of complementary notch 208 can be implemented in the prefabricated frame of second truss 204. As described above in reference to second truss 204, the complementary notches 208 may be formed in the bottom edge 206 of second truss 204 that extends to a terminus proximate the top edge 205. Each complementary notch 208 may be positioned on the span of second truss 204 such that it is aligned to engage and matingly couple to a respective one of the plurality of first notches23FH13073853.5MTV-25225108. The weight of second truss 204 supported by first truss 104 while the first notch 108 and complementary notch 208 engage may retain the first truss 104 and second truss 204 relative to one another. In various embodiments, the complementary notches 208 may be spaced regularly or irregularly, / .<?., the spacing between adjacent complementary notches 208 may vary along the length of second truss 204. Further, as shown in FIG. 2C, the top and bottom edges of second truss 204 are aligned along the z-axis, such that the plane of each second truss 204 is normal to the y-axis, however, canted second trusses 204 may be implemented depending on the application of the interlocking web.

[0133] Further, as shown in FIG. 2C, wherein each first notch 108 and complementary notches 208 extend perpendicular to their respective truss, thereby aligning and retaining first trusses 104 perpendicular to second trusses 204, angled notches may be implemented in order to retain respective sets of trusses at an oblique angle.

[0134] Referring now to FIG. 2D, an assembled interlocking web 100 is shown formed by a set of first trusses 104 and a set of second trusses 204 interlocked via the mating of each first notch 108 with a respective corresponding one of the complementary notches 208. The set of first trusses 104 is positioned perpendicular to the set of second trusses 204. When interlocked together, the set of first trusses 104 and the set of second trusses 204 form a planar top surface. The set of first trusses 104 are sized such that when interlocked with the set of second trusses 204 are the top edges 105 and the top edges 205 all lie in a plane of the top surface of interlocking web 100. Additionally, the bottom edge 106 and bottom edges 206 are aligned in a single plane and can equally contact a lower surface on which the interlocking web 100 is disposed over and effectively distribute loads throughout the web. In various embodiments, depending on the frame sizes of each of the first truss 104 and the second truss 204, bottom edges 105 and 205 may not align in a single plane. Further, in various embodiments, first notches 108 and complementary notches 208 may be sized to24FH13073853.5MTV-25225 form a top surface of interlocking web 100 of a desired planform and shape, for example, sloped, ramped, saddled, polygonal or the like.

[0135] The interlocking ability of the trusses allows for the creation of complex geometries that can be assembled to create stiffer structures. A floor joist system such as interlocking web 100, can be formed by assembling two different trusses, such as first trusses 104 and second trusses 204 as described above. Interlocking web 100 provides support for trusses in the middle, significantly increasing bending stiffness. This central support helps distribute loads more evenly across the interlocking web 100, enhancing its ability to resist deformation under heavy weights and improving overall structural stability.

[0136] The interlocking slots (notches 108 and complementary notches 208) also prevent lateral buckling in both the x and y-axes. By securely anchoring the trusses at multiple points, the design minimizes the risk of sideways or torsional movement, ensuring that the structure remains stable even under varying load conditions ( / .<?., varying live loads). This feature is crucial for maintaining the integrity of the building over time and under different stress factors.

[0137] Furthermore, the improved structural support and resistance to buckling increase the span capabilities of plastic trusses as described herein. With enhanced stiffness and stability, plastic trusses can cover larger distances without intermediate supports, making them ideal for wide-open spaces in buildings such as warehouses, auditoriums, and large commercial facilities. This increased span capability not only allows for more versatile architectural designs but also reduces the need for additional materials and supports, leading to cost savings and more efficient use of space.

[0138] The interlocking web 100, by interlocking perpendicularly, first trusses 104 and second trusses 204 provide greater stability and resistance to various forces, such as wind and seismic loads. This configuration helps distribute stresses more evenly across the25FH13073853.5MTV-25225 structure. Further, interlocking web 100 as shown in FIG. 2D may be configured for improved load distribution, perpendicular interlocking trusses can more effectively distribute both live and dead loads. This reduces the risk of structural failure and can allow for greater spans and open spaces without the need for additional support columns. One of skill in the art would appreciate that ‘live loads’ may be temporary, movable forces that change over the structure’s lifetime and ‘dead loads’ may be permanent, static weights of the structure’s own components or fixed structures fixed thereto. Further interlocking web 100 may exhibit increased rigidity, the perpendicular arrangement of first trusses 104 and second trusses 204 increases the rigidity of the overall framework, reducing deflection and movement. This is particularly beneficial in areas prone to dynamic loads or vibrations. Interlocking trusses can optimize the use of materials, potentially reducing waste and cost. The trusses' mutual support allows for lighter individual members, contributing to overall material efficiency. Further, prefabricated interlocking trusses can simplify the construction process. They can be assembled quickly on-site, reducing labor costs and construction time. The combined strength of interlocking first trusses 104 and second trusses 204 can support heavier loads, making them suitable for buildings requiring substantial load-bearing capabilities, such as industrial structures or large-span roofs. In various embodiments, the arrangement shown allows for increased design flexibility, as has been described above, in that it allows for more versatile architectural designs. Architects and engineers can create complex roof shapes and layouts while maintaining structural integrity.

[0139] In another aspect of the disclosed subject matter, and referring to FIG. 2E, an endcap 254 is shown in perspective view. Endcap 254 may take the form of a planar trussed element similar to any truss as described herein. Similarly, endcap 254 may be formed with a top cord, spaced from a bottom cord, and lateral edges extending there between to form a planar truss frame. Endcap 254 may include a plurality of internal members extending26FH13073853.5MTV-25225 between the top and bottom chords, and the lateral edges, in various embodiments. Each internal member may be oriented to form triangular cells therebetween to effectively transmit forces through the planar endcap 254.

[0140] Endcap 254 may include notched or slotted receptacles for engagement with one or more other planar frames, joists, stringers, trusses or the like. For example, as shown, endcap 254 may include slotted features 255 formed in the top cord and slotted features 256 in the bottom cord. In various embodiments, slotted features 255 may be disposed in the top chord only, leaving a linear bottom chord. The slotted features 255 may be formed in the top chord, and extend inwardly to form a receptacle configured to receive a transverse planar joist. Each slotted feature 255 may be formed having an identical dimension to accommodate a plurality of identical transverse joists. In various other embodiments, each slotted feature 255 may include varying dimensions for varyingly dimensioned joists.

[0141] Endcap 254 may include a plurality of slotted features 256 formed in the bottom chord. Slotted features 256 may be configured to receive a corresponding feature of one or more planar trusses, pillars or piles 257, shown in FIG. 2F. Pile 257 may include a forked upper end 258 forming a receptacle centrally located between two upwardly extending protrusions, the receptacle configured to matingly engage with the slotted feature 256 of endcap 254 or the linear bottom chord thereof, in embodiments lacking the slotted feature 256. Similarly to any prefabricated structural element described herein, pile 257 may be skeletonized having internal members extending between the walls thereof to form cells, which may be triangular, in various embodiments. In various embodiments, endcap 254 may include two oppositely positioned slotted features 256 positioned symmetrically along the bottom chord two matingly engage with two piles 257 shown, as shown in FIG. 2G. In various embodiments, endcap 254 may include slotted features 256 positioned as needed to accommodate piles according to a predetermined implementation. Piles 257 may be27FH13073853.5MTV-25225 configured to transmit forces exerted on the endcap 254 to the ground via the elongate bodies of the piles 254.

[0142] As discussed above in reference to FIG. 2E, endcap 254 may be configured to receive and engage with a plurality of planar joists 259 within slotted features 255. Planar joists 259 may be similar to any truss or planar frame described herein, having a perimeter formed by a top chord, bottom chord and lateral edges, with a plurality of internal members forming triangular cells therebetween. Planar joists 259 may include reinforced nodes having thicker portions proximate the points where internal members meet the perimeter chords. The plurality of planar joists 259 may be disposed within the slotted features 255 such that a bottom chord of the planar joist 259 contacts the bottommost surface of slotted feature 255. When engaged with endcap 254, the top chord of planar joists 259 may be aligned in a plane with the top chord of endcap 254 such that finishing elements, such as treads or boards can be affixed to the top chords of planar joists 259 and endcap 254 to form a walkway or floor, as shown in FIG. 2H. In various embodiments, endcap 254 may included any number of slotted features 255 to accommodate any number of planar joists 259 therein. Accordingly, endcap 254 may be configured to have any lateral width such that planar joists 259 can be appropriately spaced parallel to one another while engaged with the endcap 254. Further, as shown in FIGS. 2G, piles 257 may be engaged with the slotted features 256 disposed along the bottom chord of the endcap 254, such that each pile supports the combined weight of the endcap 254 and any engaged planar joists 259 slotted therein. The piles 257 may be configured to extend linearly downward from endcap 254 to the ground to transmit forces from live and dead loads exerting forces over the assembly.

[0143] In various embodiments, as shown in FIG. 2H, endcaps 254 may be formed having only slotted features 255 formed in a top chord thereof, with a linear bottom chord. The linear bottom chord may be configured to sit flush against a corresponding pile 257.28FH13073853.5MTV-25225Endcap 254 may include a reinforced bottom chord to maintain rigidity when spanning between piles 257. As described above, planar joists 259 extending between endcaps 254 may include reinforced nodes where internal members meet the top or bottom chords, or one of the top and bottom chords. Endcaps 254 may retain a plurality of planar joists 259 spaced transversely along the endcaps 254 to form a rectilinear planform web of interlocked prefabricated structural elements. As shown in FIG. 2H, a plurality of planar joists 259 may span between two opposite and opposing end caps 254 and retained in respective slotted features thereof, to retain the perpendicularity and spacing the of the planar joists 259. In various embodiments, planar joist 259 may be rectilinear as shown thus far. In various embodiments, planar joist 259 may include an arcuate or arch feature configured to transmit loads and maintain linearity of the top chord when spanning between successive piles, endcaps, hanger joists or the like, as shown in FIG. 21. The arch 260, for example, and without limitation, can be formed in the bottom chord of planar joist 259, having a plurality of internal members extending between the arch portion and the top chord and / or lateral edges of the planar joist 259.

[0144] An embodiment as shown in FIG. 2H was subjected to real-life testing. Accordingly, a 4 ft x 8 ft floor system was designed using four trusses on 16 in. centers and a plywood floor surface. Three different types of structures were additively manufactured: the floor joists (trusses) 259, end caps (girders) 254 and pile footings 257. The joists and endcaps may each be one in. thick. In various embodiments, the joists and endcaps may be as thick as required to transmit loads based on the predetermined truss design and implementation. The last component is a 4 ft x 8 ft - 15 / 32 in. thick plywood sheet attached to the joists with selftapping screws.

[0145] The trusses were put into the end caps with a snug fit. The plywood was fastened to the trusses with 1 14 in drywall screws. A pilot hole was drilled first and the29FH13073853.5MTV-25225 plywood was rolled up- screwed from one end to the other. The end caps rest on the piles held by gravity. The load-displacement testing was conducted by loading the structure with 48 lb. sand bags, 60 lb. concrete bags, and 45 lb. weight room plates. Displacement measurements were made at the bottom of one of the middle joists, at the middle of the joist.

[0146] Testing occurred over three different days. The load was placed in the center of the structure and the testing was cyclic. Load was placed on the floor in increments, with measurements taken after each increment was placed and the load was removed at the same increments with measurements taken after each increment was removed. The dial gauge was zeroed before the start of each day of testing. On the first day of testing the max load was 384 lbs. and load was placed in increments of 48 lbs. and bags with 5 cycles completed. On day two of testing, the max load with a measurement was 1134 lbs., with loads of 330, 660, 852, and 1044 lbs. also tested and measured using the concrete bags and sand bags with one cycle completed. On day three of testing was, the max load was 1074 lbs. with loads of 360, 600, 792, and 984 lbs. tested which are different from day two due to a broken concrete bag and 3 cycles were completed. The bags were manually loaded onto the structure, then put into the middle. Loading of the structure would cause vibration and sudden impact to the structure. The stiffness of each cycle was roughly the same, 3,835 lb. / in. Calculating stiffness by testing cycle eliminates the error from offsets that were seen during testing. The average stiffness of the cycles was 3,835 lb. / in with a standard deviation of 0.35 lb. / in.

[0147] Simulations were again performed where the floor was simulated with the endcaps constrained at the corners and a 0.05 in cut of a rectangular shape the size of the testing load where a point load is placed on the bottom of the cut. The load-displacement data from the simulation remained over the range of 0-400 lbs., and yielded an overall stiffness of 4,009 lb. / in.30FH13073853.5MTV-25225

[0148] A series of experiments over several days to measure the floor deflection with loads well above the HUD limit of 300 lb. were conducted. Loads up to 1,200 lb. were applied, again with successive loading and unloading. While shifts to the right (deflection offsets) were again observed between tests, the within test stiffness remained consistent with that of the simulation and low load tests. Finally, an ultimate load test was performed, adding weight until a clear structural failure occurred. The floor system finally failed at 4,480 lbs., when two truss chords buckled and fractured.

[0149] Referring now to FIG. 3, a schematic representation of a ramp joist system 300 is shown in trimetric view. The interlocking nature of the trusses can be applied to create stair or ramp joist systems. Both of these systems consist of stringers that span the length of the stair / ramp. The stringers have notches in which treads slot into. The treads are able to support the weight of the boards that they carry along with people that use those systems.The treads might take a similar form to the trusses presented in the webbed floor system, as shown above in FIGS. 2C-2D.

[0150] Ramp joist system 300 may include a first truss 304 and a second truss 404. For the purposes of this disclosure, first truss 304 may be referred to as a stringer 304 and second truss 404 may be referred to as a tread 404. Stringer 304 may be structurally similar to first truss 104 in reference to FIG. 1 A. The stringer 304 may be an elongate member extending from a proximal end to a distal end. The proximal end may be at a first elevation and the second end may be at a second elevation, wherein the second elevation is lower than the first elevation, / .<?., the stringer 304 may be sloped between its two ends. Stringer 304 may include a top edge spaced from a bottom edge, wherein the top edges and bottom edges are substantially parallel to one another. Stringer 304 may include angled portions at the proximal end and distal end, configured to rest on a landing and / or a ground area, respectively. Further, similarly to first truss 104, stringer 304 may include a plurality of31FH13073853.5MTV-25225 internal members 307 (as shown in FIGS. 4A-4B) extending between a top edge (or top chord) 305 and a bottom edge (or bottom chord) 306. In various embodiments, internal members 307 may extend between a top edge 305 and another internal member 307 and / or between a bottom edge 306 and another internal member 307. The internal members 307 in concert with the top edge 305 and bottom edge 306 may form triangular sections, or trusses. In various embodiments, a portion of the internal members 307 may be formed perpendicular to the ground, therefore at an oblique angle to the top edge 305 and the bottom edge 306. In various embodiments, a portion of the internal members 307 may be formed normal to at least one the top edge 30 and the bottom edge 306.

[0151] Further in similarity to first truss 104 shown in FIG. 1 A, stringer 304 may include a plurality of first notches 308 formed in the top edge 305. The plurality of first notches 308 may be formed as a recess, groove or cutout in stringer 304. Each first notch 308 may be formed at an angle to top edge 305, such as normal to a ground level. In various embodiments, each first notch 308 may be formed normal to top edge 305. In various embodiments, there may be any number of first notches 308 formed between the proximal and distal ends of stringer 304, at regular intervals or irregular intervals. In various embodiments, each first notch 308 may be formed at an apex of at least two internal members 307, as shown in FIGS. 4 A and 4B. As described herein, each stringer 304 may be formed as a rigid planar frame.

[0152] With continued reference to FIGS. 3, 4 A, and 4B, a plurality of stringers 304 may be oriented parallel and adjacent to one another along a y-axis (as shown in FIG. 3). Ramp joist system 300 may include a plurality of treads 404. Treads 404 may be similar to second truss 204 as described above. Treads 404 may include a top edge 405 and a bottom edge 406. Each tread 404 may extend from a second proximal end to a second distal end, and oriented perpendicularly to the stringers 304. Utilizing the axes of FIG. 3, each tread 40432FH13073853.5MTV-25225 may extend along the y-axis. Treads 404 may include a plurality of complementary notches 408 formed in the bottom edge 406. Each complementary notch 408 may be formed such that the bottom of said notch is proximate the top edge 405, / .<?., the complementary notch 408 extends across the height of each tread 404. Each tread 404 may include any number of complementary notches 408 spaced along the bottom edge 406 and at regular or irregular intervals. Each complementary notch 408 may be shaped to receive and matingly engage with a corresponding one of the plurality of first notches 308 of the stringers 304.

[0153] In various embodiments, first notch 308 or complementary notch 408 may include features that retain another truss therein, such as bosses, snaps, or the like. In various embodiments, notch 308 and / or complementary 408 may be configured to temporarily or permanently retain another truss matingly therein, such as compliant features configured to snap into place upon coupling of distinct trusses together. In various embodiments, notch 308 and / or complementary notch 408 may have an adhesive applied prior to coupling distinct trusses. In various embodiments, a downstream manufacturing step may be applied to notch 308 and / or complementary notch 408 to retain a distinct truss therein, such as mechanical fastening or the like.

[0154] Each tread 404 may be formed as a rigid planar framework having a plurality of internal members 407 extending between top edge 405 and bottom edge 406. In various embodiments, a portion of internal members may extend between top edge 405 and another internal member 407. In various embodiments, a portion of internal members 407 may extend between a bottom edge 406 and another internal member 407.

[0155] Each tread 404 may be oriented upon engagement with each stringer 304 such that tread 404 is oriented normal to ground level. In various embodiments, each tread 404 may be engaged with stringer 304 such that tread 404 is normal to stringer 304. As shown in FIG. 3, each tread 404 may descend relative to the immediately preceding tread 404 along33FH13073853.5MTV-25225 stringer 304. In various embodiments, each tread 404 may align vertically (along the z-axis) with a portion of internal members 307 of stringers 304.

[0156] In various embodiments, at least a portion of stringers 304 and treads 404 may be formed through large scale additive manufacturing, such as 3D printing, among others. In various embodiments, stringer 304 and / or treads 404, and any truss as described herein, may be formed from plastic, fiber-reinforced plastic or a similar material, such as recycled plastic. Plastic may be used in truss construction offers several key benefits over wood and metal construction. For example, and without limitation, plastic trusses are highly resistant to corrosion, making them ideal for environments with moisture or chemicals, and they require significantly less maintenance, as it would not rust, rot or require painting. For example, and without limitation, plastic trusses may be lightweight and therefore simplify transportation, handling, and installation, reducing the load on building foundations. For example, and without limitation, plastic trusses may be beneficial because of plastic material’s moldability, which may allow for innovative design possibilities, and its thermal insulative properties may contribute to energy efficiency. For example, and without limitation, many plastics are recyclable and can be produced more resource-efficiently compared to traditional materials.

[0157] In various embodiments, at least a portion of stringers 304 and / or treads 404 may be formed from a composite material or a polymer. In various embodiments, at least a portion of stringers 304 and / or treads 404 may be formed at least in part by acrylonitrile butadiene styrene (ABS) and / or ABS with carbon fiber filaments embedded therein (ABS CF). In various embodiments, at least a portion of stringers 304 and / or treads 404 may be formed at least in part by metal or a metal alloy.

[0158] Referring now to FIG. 5, 6A and 6B assembled and exploded trimetric views and a side exploded view of a stair joist system 500 is shown. Stair joist system 500 utilizes the interlocking nature of trussed elements forms a prefabricated web suitable for stair34FH13073853.5MTV-25225 construction. The system may include a plurality of stringers 504 that span between an upper landing and a lower landing, and a plurality of treads 604 that slot into notches in the stringers 504 to support loads exerted on the stair joist system 500.

[0159] Each stringer 504 may be an elongate, inclined truss joist frame extending between a first proximal end at a higher elevation and a first distal end at a lower elevation, such that a user could ascend or descend on the stair joist system 500. Each stringer 504 may have any number of stepped surfaces defined regularly between the first proximal end and first distal end by periodic stepped top surfaces 505 formed by successive horizontal portions connected by vertical members. Each stringer 504 may include an inclined bottom chord 506 spaced from the top chord and extending substantially parallel to the top chord. In various embodiments, bottom chord 506 may be substantially linear, or include stepped surfaces at the same or varying periodicity as the top chord.

[0160] Each stringer 504 may include a plurality of internal members 507 that extend between the top chord and the bottom chord 506 to form a rigid planar truss. In various embodiments, the plurality of internal members 507 may be arranged to create triangular or other lattice geometries and may extend between the stepped top surface 505 and another internal member 507. In various embodiments, the plurality of internal members 507 may extend between the bottom chord 506 and another internal member 507. In various embodiments, the plurality of internal members may extend between the stepped top surface 505 and the bottom chord 506. In various embodiments, a portion of the internal members 507 are formed substantially perpendicular to ground or substantially normal to at least one of the chords to optimize load paths.

[0161] The stepped top surface 505 includes a plurality of regularly descending step surfaces from the first proximal end to the first distal end. A plurality of first notches 508 are disposed along the stepped top surface 505. Each first notch 508 is formed as a recess,35FH13073853.5MTV-25225 groove, or cutout shaped to receive a complementary feature of a tread 604, to be described below. The plurality of first notches 508 may be oriented normal to the local plane of the step surface, normal to ground, or at another angle suitable for transfer of vertical and lateral loads.

[0162] In various embodiments, any number of the plurality of first notches 508 may be provided at regular or irregular intervals. In some embodiments, each first notch 508 is located at or proximate an apex where at least two internal members 507 meet, thereby delivering notch reaction forces directly into the truss.

[0163] In various embodiments, each stepped surface of the stepped top surface 505 may include two first notches 508. In various embodiments, one of the first notches 508 of a single step may be disposed proximate a proximal edge of a respective step surface and the second first notch 508 of the respective single step may be disposed proximate a distal edge of the respective step surface, thereby accommodating multiple tread 604 engagement points per step and enabling alternate tread orientations or widths.

[0164] As shown in FIGS. 5, 6A and 6B, a plurality of stringers 504 may be positioned parallel and adjacent to one another to define a stair width. A plurality of treads 604 may be configured to be regularly positioned along the stringers 504 from the upper landing to the lower landing. Each tread 604 extends between a second proximal end and a second distal end and spans perpendicular to the plurality of stringers 504.

[0165] In various embodiments, each tread 604 includes a top edge, a bottom edge spaced from the top edge, and a plurality of internal members extending between the top and bottom edges to form a rigid planar truss. The bottom edge of each tread 604 may be formed to have a plurality of complementary notches 608 sized and shaped to matingly engage respective first notches 508 of the stringers 504. In some embodiments, each complementary notch 608 extends substantially across the height of the tread 604 such that, upon36FH13073853.5MTV-25225 engagement, bearing surfaces of the complementary notch 608 seat fully within a corresponding one of the plurality of first notches 508.

[0166] In various embodiments, during assembly, each first notch 508 may receive a corresponding complementary notch 608 of a tread 604, thereby forming an interlocking web between the stringers 504 and the treads 604. In various embodiments, a subset of first notches 508 and complementary notches 608 are configured to engage. When engaged, the top edge of each tread 604 aligns with and is supported by a respective step of the stepped top surface 505, while the top edge of each stringer 504 coincides with its stepped top surface 505. The treads 604 may descend stepwise along the stringers 504 and may be positioned to align vertically with selected internal members 507 of the stringers 504 to promote direct load transfer.

[0167] In various embodiments, each tread 604 may be oriented at an oblique angle relative to the stringers 504 while still extending perpendicular thereto in plan, for example to accommodate non-orthogonal details, skewed stair geometries, or aesthetic patterns, while maintaining full notch engagement with the first notches 508 on the stepped top surface 505.

[0168] The first notches 508 and / or the complementary notches of the treads 604 may include retention features to temporarily or permanently couple the components, including integral bosses, snaps, compliant interference features, adhesives applied prior to assembly, or downstream fastening such as pins, screws, rivets, or clamps utilized alone or in combination to prevent decoupling or unintended structural shear or stress.

[0169] In various embodiments, each stringer 504 and each tread 604 are additively manufactured. In various embodiments, at least a portion of the stringers 504 and / or treads 604 are additively manufactured. The stringers 504 and treads 604 may be formed from plastic or fiber-reinforced plastic, from composite materials, from metal or metal alloys, or from recycled materials. In some embodiments, the stringers 504 and treads 604 include37FH13073853.5MTV-25225 acrylonitrile butadiene styrene (ABS) with carbon fiber filaments embedded therein. Material selections may be made to provide corrosion resistance, weight reduction, manufacturability, recyclability, and thermal or acoustic performance.

[0170] The geometry, count, and spacing of the first notches 508 and the complementary notches of the treads 604 may be varied to suit different rise / run configurations, load requirements, and building codes. Likewise, the arrangement, size, and density of internal members 507 in both the stringers 504 and treads 604 may be tailored for strength, stiffness, weight, and manufacturability, while maintaining the interlocking function of the stepped top surface 505, first notches 508, and the complementary notches 608 of mating treads 604.

[0171] Referring now to FIGS. 7A-8F, exemplary representations of roof truss systems 700 and various trusses (which may alternatively be called roof joists) 704 configurable for use therefor are shown. Roof truss system 700 may be formed as an interlocking web of prefabricated structural elements, such as first planar trusses 704. In various embodiments, first planar truss 704 may define a first perimeter that is substantially triangular and includes a base 706 and at least one sloped portion 705 that, together with the base 706, bounds the perimeter.

[0172] In various embodiments, first planar truss 704 may be formed as a rigid planar frame and includes at least one first internal member 707 spanning the first perimeter. In various embodiments, a plurality of first internal members 707 cooperatively form triangular cells between the base 706 and sloped portion 705.

[0173] As shown in FIG. 7B, first planar truss 704 may include a plurality of linear internal members 707 forming triangular cells. Additionally, or alternatively, and in various embodiments, the internal members 207 may be non-linear and therefore form non-tri angular cells within the perimeter of first planar truss 704. As shown specifically in FIG. 7C, internal38FH13073853.5MTV-25225 members may be arched, forming a semicircular or circular section-shaped cell within the perimeter of the planar truss. Additionally, or alternatively, and in various embodiments, internal members may be selectively shaped to form unique and customizable cells within the planar truss, such as heart-shaped cells. Further, the internal members may be formed symmetrically within the planar trusses 704, or asymmetrically, such that internal members attain nonregular angles and incongruent cell shapes and sizes with planar truss 704. Any roof joist or planar truss configured for use in a roof joist system may include a perimeter that is substantially triangular, including such perimeters having radiused, chamfered, or linear corners.

[0174] In various embodiments, first planar truss 704 may include at least one first notch 708. In various embodiments, first planar truss may include a plurality of first notches 708. In various embodiments, first notch 708 may be formed in the first perimeter, for example in base 706 and / or sloped portion 705, and / or may be formed through at least one first internal member 707. In various embodiments, first notch 708 may be formed by the junction of one or more of sloped portion 705, base 706 and one or more internal members 707. In various embodiments, first notch 708 may be a recess, groove, slot, or cutout having a profile configured to receive a complementary notch of a mating truss, to be described below.

[0175] The combined strength of interlocking trusses can support heavier loads, making them suitable for buildings requiring substantial load-bearing capabilities, such as industrial structures or large-span roofs. In various embodiments, the arrangement shown allows for increased design flexibility, as has been described above, in that it allows for more versatile architectural designs. Architects and engineers can create complex roof shapes and layouts while maintaining structural integrity. Accordingly, the system 700 may include at least one second planar truss 704' having a second perimeter. In various embodiments, the39FH13073853.5MTV-25225 second perimeter is substantially triangular and includes a second base 706' and a second sloped portion 705'. Second planar truss 704' includes at least one second internal member 707' spanning the second perimeter and at least one complementary notch 708' shaped to matingly engage first notch 708 of first planar truss 704. Second planar truss 704' may include any configuration as described herein, including an identical configuration as first planar truss 704.

[0176] Complementary notch 708' may be formed in the second perimeter, such as in second base 706' or second sloped portion 705', and / or in a second internal member 707'. As described above in reference to first planar truss 704, the complementary notch 708' may be formed by a junction between two members, including sloped portion 705', base 706' and one or more internal members 707'. Upon assembly, complementary notch 708' is received by first notch 708, thereby coupling first planar truss 704 and second planar truss 704' and constraining their relative translation and rotation.

[0177] In various embodiments, first planar truss 704 and second planar truss 704' may be interlocked to form roof joist system 700. In some embodiments, roofed truss system 700 includes a plurality of second planar trusses 704', each having at least one complementary notch 708' configured to matingly engage first notch 708 of first planar truss 704 and / or a complementary notch 708' of an adjacent second planar truss 704'. The resulting interlocking engagement yields a web beneath and / or along sloped portions 705, 705' that creates a roofed lattice capable of distributing load across multiple planes.

[0178] In various embodiments, roofed truss system 700 may include a plurality of first trusses 704 and a one or more second planar trusses 704', of common or varying configuration. In various embodiments, any number of first planar trusses 704 and second planar trusses 704' may be coupled together normally or at an angle. For example, the plane of second planar truss 704' may be normal, acute, or obtuse relative to the plane of first40FH13073853.5MTV-25225 planar truss 704 when a complementary notch 708' engages a corresponding one of first notch 708. In various embodiments, the angular relationship is selected so that sloped portions 705, 705' collectively provide a predetermined roof pitch.

[0179] As described above in reference to systems 100, 300 and 500, the plurality of notches 708, 708', or a portion thereof may incorporate retention features, such as undercuts, bosses, compliant tabs, detents, snaps, dovetail forms, key-and-keyway interfaces, or apertures for mechanical fasteners. Adhesives, welding, thermal staking, or fasteners may be applied at or after assembly to effect temporary or permanent retention.

[0180] In various embodiments, the position of a first notch 708 and / or a complementary notch 708' may coincide with an intersection or apex of internal members (e.g., first internal member 707 or second internal member 707'). Notches 708, 708' may extend partially through the thickness or fully through the members and may include tapers to draw mating faces together such as used in joinery.

[0181] First planar truss 704 and second planar truss 704' may be formed as any truss, with any number of sides and internal members, such as those shown in FIGS. 8A-8F, for example. First planar truss 704 and / or second planar truss 704' may be configured as any of the following truss types: kingpost, fink, double fink, dual pitch, inverted, queenpost, modified queenpost, gambrel, piggyback, hip, Polynesian, studio, howe, double howe, scissors, attic, cathedral, fan, monopitch, bowstring, flat, sloping flat, cambered, or stub roof joist. Distinct types may be combined within the same roofed truss system 700 to tune stiffness, span, and geometry. These truss types are shown in FIGS. 8A-8F.

[0182] In one embodiment, first and second perimeters are triangular frames in which bases 706, 706' serve as lower chords and sloped portions 705, 705' converge to a ridge. First notches 708 may be positioned along sloped portions 705 at regular or irregular intervals, and complementary notches 708' may be aligned along second bases 706', such that assembled41FH13073853.5MTV-25225 second planar trusses 704' bridge between spaced first planar trusses 704 to form a roofed web.

[0183] At least a portion of first planar truss 704 and second planar truss 704' may be additively manufactured, including large-scale 3D printing. Materials may include plastics or fiber-reinforced plastics, composites, and metals. In particular embodiments, the trusses include acrylonitrile butadiene styrene (ABS) with carbon fiber filaments embedded therein (ABS CF). In further embodiments, at least a portion of the trusses are formed from recycled material. In various embodiments, at least a portion of the trusses may be additively manufactured among other operations, such as printing the main truss and insertion of other components such as inserts, bushings, coatings or the like to manage wear and tear, or to weatherproof the roofed truss system 700 prior to assembly.

[0184] In assembly, multiple first planar trusses 704 may be spaced along a span, and a plurality of second planar trusses 704' are indexed into distributed first notches 708 located along bases 706 and / or sloped portions 705. The interlocked array forms a roofed interlocking web that supports sheathing, membranes, or modules applied to sloped portions 705, 705', while loads are transmitted through internal members 707, 707' and across planes via engaged notches 708, 708'. The resulting structure is lightweight, corrosion-resistant, and configurable in pitch, span, and topology.

[0185] As shown in FIG. 7A, roofed truss system 700 may be formed as a series of parallel and adjacent first trusses 704 having any number or arrangement of second trusses 704' coupled thereto according to the teachings above via interlocking notches to form any roof configuration desired.

[0186] Referring now to FIG. 9A-9D, side views of trusses 900a-900d are shown. Trusses 900a-900d may be additively manufactured as described above. In various embodiments, trusses 900a-900d may be wholly additively manufactured or 3D printed.42FH13073853.5MTV-25225Truss 900a may be a single-bead print, having no upper chord. Trusses 900b-904d may be similar to truss 900a with the addition of an outer rectangle, leading to a single bead upper chord and double bead lower chord. Simulation was performed on the designs of trusses 900a-900d, wherein a single layer of each design was analyzed for single layer weight (lb.) and single layer print time (s), 900a may have a single layer weight of 0.42 lbs. and single layer print time of 64 s. 900b may have a single layer weight of 0.79 lbs. and single layer print time of 110 s. 900c may have a single layer weight of 0.75 lbs. and single layer print time of 102 s. 900d may have a single layer weight of 0.86 lbs. and single layer print time of 120 s.

[0187] In various embodiments, trusses 900a-900d may be partially additively manufactured, such as printing the main rigid frame and mechanically fastening one or more components thereto. In various embodiments, trusses 900a-900d may be utilized in the systems described herein, namely 300, 500 and 700. For example, and without limitation, trusses 900a-900d may be utilized in the floor web system 300 as either the first truss 104 or second truss 204 - or both. Truss 900a may include a bottom chord and lateral sides and internal members forming triangular cells therebetween. Truss 900b may be similar to 900a with a bead formed about the perimeter of the bottom chord, lateral sides, and spanning across the top edge therebetween, bounding the internal members. Internal members may vary in angle and number, as shown in trusses 900c and 900d. As shown, truss 900c may include a lesser total number of internal members, such as four internal members, formed at obtuse angles spanning the length of the truss to form five triangular cells. As shown, truss 900d may include a greater number of internal members formed at acute angles alternatingly forming triangular cells along the span of the truss. Any truss, planar frame, joist, stringer or tread may be formed from polymers, composites, or metals, each of which may be configured for additive manufacturing.43FH13073853.5MTV-25225

[0188] In various embodiments, any of trusses 900a, 900b, 900c, and 900d may be elongate, substantially planar truss bodies additively manufactured from any of the aforementioned materials. Each truss may include one or more longitudinal chords joined by a plurality of internal members (e.g., a triangulated lattice), wherein the overall thickness and the count and arrangement of internal members are selected to meet application-specific load and weight targets.

[0189] In certain embodiments, trusses 900a-900d may be approximately 8-foot-long truss having a nominal thickness of about one inch. When printed in ABS CF, such a truss weighs about ten pounds and can be fabricated in approximately ten minutes using an additive manufacturing process. Trusses 900a-900d may provide strength comparable to a conventional softwood 2^6 board while offering substantially reduced mass.

[0190] Any truss described herein may be customized by increasing thickness of any members while maintaining a similar internal member topology to enhance stiffness for higher-load applications, still leveraging the lightweight ABS CF construction.

[0191] Any truss described herein may be customized by varying the number and / or density of internal members at a given thickness to tailor strength-to-weight ratio and material usage, enabling optimization for specific span, deflection, or fabrication-time constraints.

[0192] Across these embodiments, the trusses may be characterized by: low mass (e.g., an eight-foot, one-inch-thick ABS CF truss at about tent pounds), rapid fabrication (e.g., about ten minutes print time for the foregoing configuration), strength comparable to wooden joists, and configurability via thickness and internal member count to meet diverse structural requirements.

[0193] Truss 900b was additively manufactured utilizing 3D printing in ABS CF and subjected to physical testing, the results of which are shown in Table I. In one evaluation,44FH13073853.5MTV-25225 loads up to 180 pounds were placed on a platform supported by the truss. Two specimens (truss 1 and truss 2 in Table I) were produced and tested under this setup. The stiffness required to meet HUD standards is -197,000 N / m for an eight-foot span, truss 2 meets that standard as shown in Table I.Table I: Results from testing.

[0194] A simulation of the truss in 3 point bending was performed. The initial use of the simulation was to determine which design should be moved forward at the large scale with a comparison of relative k / w ratios. For the simulation the truss is constrained on the bottom edges, with a small platform in the center to apply a point load. The top measurement point was used for k / w comparison amongst the different designs, while the bottom measurement point was used for the experiments.

[0195] The simulation was performed on trusses 900b-900d (900a was not simulated), with a simulated load of 180 lb. The results of the simulation are shown below inTABLE II.Table II: k / w ratios of 900b-900d with 180 lb. load.45FH13073853.5MTV-25225

[0196] The truss 900b was further subjected to simulation testing. The simulation done on 900b was refined to reflect the deflection seen in testing. Constraints and load placement were refined with results shown in Table III. Simulation and testing data agreeing is a sign that that the simulation is correct and can be used confidently in the design of structures. Table III shows the agreement between the simulated and testing data of truss 2. The error being 10% or less is incredibly small and shows good agreement between the testing and simulation.Table III: Comparison between testing and simulation data.

[0197] With confidence in the single truss simulation, it is possible to explore the design space to find the truss with the maximum stiffness to weight (k / w) ratio. Using the same truss design (900b with 5 nodes) and keeping the length the same (8 ft), the height of the truss can be easily varied both in design and in manufacture. The height of the prototypes used here is 13 in. Using the simulation conditions discussed above, the height was varied to 10, 15, 17, and 19 in. Based on the results of the simulations, and using a quadratic curve fit to the data, the maximum value of k / w was at truss height of 16.3 in.

[0198] Referring now to FIG. 10A and 10B, prefabricated structural elements for construction of an interlocked floor system according to various aspects of the present disclosure is shown. Shown specifically in FIG. 10A, a hanger joist 1004 forming a planar trussed frame, may include a generally rectilinear shape with a top chord 1005, bottom chord1006 and internal members 1007. Internal members 1007 may be distinct internal members1007 or a continuously printed and joined internal member 1007, bonded to the top chord 1005 and bottom chord 1006 to form a slotted feature 1008 therebetween. As shown in FIG.46FH13073853.5MTV-2522510A, each internal member section may be designed to form slotted features 1008 having a predetermined size to accommodate one or more notched features of planar joists 1012 coupled thereto. In various embodiments, hanger joist 1004 may include a plurality of rectilinear slotted features 1008 to receive a corresponding sized and shaped protrusion extending from the planar joists 1012. In various embodiments, each slotted feature 1008 may be bounded completely by the internal members 1007, top chord 1005 and bottom chord 1006, or open at one or more ends thereof. For example, and without limitation, each slotted feature 1008 may be configured with an opening through top chord 1005 similar to end cap 254, or the first and second trusses 104, 204. Hanger joist 1004 may include any number of slotted features 1008 with identical or differing internal dimensions and geometries spaced along the length of hanger joist 1004. For example, and without limitation, hanger joist 1004 may be configured to receive planar joist 1012 having differing thicknesses, such as thicker planar joists 1012 at the first and second ends of hanger joist 1004, with relatively thinner planar joists 1012 coupled to and spaced along the intermediate portion of hanger joist 1004. For example, and without limitation, hanger joist 1004 may include larger slotted portions at its two ends and the middle portion thereof, to receive relatively thicker planar joists 1012 coupled therein. In various embodiments, hanger joist 1004 may include linear top chord 1005 and bottom chord 1006, or an arched chord disposed along the bottom or top edge.

[0199] Referring now to FIG. 10B, a planar joist 1012 for construction of prefabricated structural elements is shown. Planar joist 1012 may be similar to any truss, frame, or joist as described herein, being formed as a planar frame having a top chord 1013, bottom chord 1014 with a plurality of internal members 1015 extending therebetween. The internal members 1015 may intersect or bond with the perimeter of the planar joist 1012 to form generally triangular sections therebetween. Similarly to FIG. 10 A, internal members 1015 may be formed from linear or non-linear members, or a combination thereof to form47FH13073853.5MTV-25225 triangular or non-tri angular cells therebetween. Planar joist 1012 may include protrusions 1016 extending from the lateral edges thereof, each protrusion 1016 configured to slot within and engage with the slotted features of hanger joist 1004. Protrusions 1016 may extend from the top chord 1013 to the bottom chord 1014, or only a portion thereof. Further, protrusions 1016 may be of any dimension and shape to matingly engage with and be retained within the slotted portions 1008. In various embodiments, a plurality of planar joists 1012 may be slotted within hanger joist 1004 and spaced transverse thereto, such that each planar joist 1012 is parallel to one another when slotted into hanger joist 1004. Accordingly, a second hanger joist 1004 may be disposed on an opposite end of the plurality of planar joists 1012 such that each planar joist 1012 spans from the first hanger joist 1004 to a second hanger joist 1004. In such an arrangement, each hanger joist 1004 may be mirror images of one another, or be otherwise bilaterally symmetrical.

[0200] In various embodiments, an interlocked floor web 1020 can be formed by a at least one hanger joist 1004 and a plurality of planar joists 1012 slotted into and coupled thereto. A plurality of planar joists 1012 may be configured to span between hanger joists 1004, substantially perpendicular to the hanger joists 1004. The plurality of planar joists 1004 are slotted into corresponding slotted features 1008 via their protrusions 1016 to establish a self-indexing interlock that aligns and maintains the planar joists 1012 in parallel. The interface between protrusions 1016 and slotted features 1008 may be configured for friction or interference fit. In various embodiments, the protrusions 1016 and be secured within the slotted features 1008 via adhesives, mechanical fasteners, integral mating features like detents or bosses, fillets, chamfers, welds, fused joints, locking tabs, or the like. The relative spacing and orientation of the plurality of slotted features 1008 within hanger joist 1004 dictate the spacing and orientation of the plurality of planar joists 1012, enabling uniform distribution of planar joists 1012 along the hanger joist 1004. A portion of the48FH13073853.5MTV-25225 slotted features 1008 may be sized to accommodate variable thickness planar joists 1012, such as thicker planar joists 1012 at the two ends of hanger joist 1004 and midspan of hanger joist 1004.

[0201] When assembled, the opposing hanger joists 1004 serve as lateral collectors while the network of internal members 1007, 1015 within the interconnected frames distributes loads and enhances in-plane stiffness; a deck or sheathing layer affixed to the top chords 1005, 1013 may further stiffen the assembly. The system may be configured for permanent installation or reversible assembly to permit modular construction, transport, and reconfiguration.

[0202] As shown in FIG. 11 A, an end side wall stud 1030 is shown. End side wall stud 1030 may be formed as a monolithic additively manufactured elongate body that has opposite end portions. A lower shoulder end 1031 may include a central protrusion that projects axially beyond adjacent flat portions. The flat portions may extend laterally from opposite sides of the protrusion to form planar shoulders that are generally coplanar with one another and set back from the protrusion. The shoulders may be configured as bearing faces that limit insertion depth and distribute loads when the end side wall stud 1030 is coupled to the planar joists 1012 at the shoulder end 1031. End side wall stud 1030 may include a forked end 1032 at an opposite end from shoulder end 1031. The forked end 1032 may include two spaced protrusions that form a central receptacle therebetween, sized to receive one or more other prefabricated structural elements, such as a roof joist as described above. The protrusions of forked end 1032 may extend axially from the elongate body of end side wall stud 1030 to form bearing faces inwardly facing the central receptacle. Forked end 1032 may include one or more integral retention features like detents, lands or bosses emplaced within the receptacle. As shown in FIG. 1 IB, end side wall stud 1030 may be configured to engage with one or more planar joists 1012 at the shoulder end 1031. As can be seen on the49FH13073853.5MTV-25225 lefthand side of FIG. 11B, the protrusion of shoulder end 1031 of side end wall stud 1030 may be sandwiched between planar joists 1012, and in various embodiments, planar joists 1012 of different thickness, such as 1” and 2” respectively. The flat shoulder portions of should end 1031 may be configured to interface with the top chords of the planar joists 1012, retaining the end side wall stud 1030 to extend upwardly from the interlocking web 1020, which was formed as an assembly of planar joists 1012 and hanger joists 1004. A side view of a structure formed from prefabricated structural elements including the interlocking web 1020 having a plurality of end side wall studs 1030 extending upwardly therefrom can be seen in FIG. 1 IB. Further, as shown in FIG. 11C, a roof joist is shown retained in the forked end 1032 of a series of end side wall studs 1030. The roof joist is shown commonly received by the plurality of forked ends 1032 which are intermittently disposed about the base of the triangular roof joist.

[0203] Referring now to FIGS. 12A-12C, various wall studs for structures formed by prefabricated structural elements are shown. In FIG. 12A, hanger side wall stud 1040 is shown with a lower shoulder end 1041 and an upper shoulder end 1042. Hanger side wall stud 1040 may be formed as a monolithic additively manufactured elongate body that has opposite end portions. A lower shoulder end 1041 may include a protrusion that projects axially beyond an adjacent flat portion. The flat portion may extend laterally from one side of the protrusion to form planar shoulder that is set back from the protrusion. The shoulder may be configured as a bearing face that limits insertion depth and distributes loads when the hanger side wall stud 1040 is coupled to the planar joists 1012 at the shoulder end 1041. The protrusion of shoulder end 1041 may extend the entire distance across the hanger side wall stud 1040. Additionally, or alternatively, the shoulder end 1041 may include a lateral extend notched portion transverse to the longitudinal axis of the elongate body. Hanger side wall stud 1040 may include an upper should end 1042 formed by a protrusion extending axially50FH13073853.5MTV-25225 from the elongate body and an adjacent flat portion extending laterally therefrom and spaced from the protrusion tip. The upper shoulder end 1042 may include additional internal members to increase rigidity, in various embodiments. The upper shoulder end 1042 may be configured to engage with a base of a roof joist 704 at an end of a structure, thereby delimiting the roof portion. The flat shoulder portion of upper shoulder end 1042 may be configured to retain the base of the roof joist 704 while the protrusion of upper shoulder end 1042 limits the lengthwise movement of the roof joist 704 by extending upwardly and contacting points on the planar face of the roof joist 704 as shown in FIG. 12G.

[0204] In FIG. 12B, a hanger side corner stud 1050 is shown with a lower shoulder end 1051 and an upper rectilinear end 1052. Hanger side corner wall stud 1050 may be relatively thicker than the outer corner stud 1060 shown in FIG. 12C. Hanger side corner stud 1050 may be formed as a monolithic additively manufactured elongate body that has opposite end portions. A lower shoulder end 1051 may include a protrusion that projects axially beyond an adjacent flat portion. The flat portion may extend laterally from one side of the protrusion to form planar shoulder that is set back from the protrusion. The shoulder may be configured as a bearing face that limits insertion depth and distributes loads when the hanger side corner stud 1050 is coupled to the planar joists 1012 at the shoulder end 1051. Hanger side corner stud 1050 may include an upper rectilinear end 1052. Rectilinear end 1052 may be coextensive with the elongate body, including extra internal members to increase rigidity at the rectilinear end 1052, in various embodiments.

[0205] In FIG. 12C, an outer corner wall stud 1060 is shown with a lower shoulder end 1061 and an upper rectilinear end 1062. Outer corner wall stud 1060 may be formed as a monolithic additively manufactured elongate body that has opposite end portions. A lower shoulder end 1061 may include a protrusion that projects axially beyond an adjacent flat portion. The flat portion may extend laterally from one side of the protrusion to form planar51FH13073853.5MTV-25225 shoulder that is set back from the protrusion. The shoulder may be configured as a bearing face that limits insertion depth and distributes loads when the outer corner wall stud 1060 is coupled to the planar joists 1012 at the shoulder end 1061. Outer corner stud 1060 may include an upper rectilinear end 1062. Rectilinear end 1062 may be coextensive with the elongate body, including extra internal members to increase rigidity at the rectilinear end 1062, in various embodiments.

[0206] Referring now to FIG. 12D, a joint formed by hanger joist 1004, planar joists 1012 and hanger side wall studs 1040 is shown in two orthogonal views. On the lefthand side, the transverse hanger joist 1004 is shown retaining planar joists 1012 slotted into respective slotted features extending the length of hanger joist 1004. Further, hanger side wall stud 1040 may be coupled to one or both of the hanger joist 1004 and planar joist 1012 at the intersection thereof, wherein the flat shoulder portion of the lower shoulder end 1041 overlays one or both of the top chords of the hanger joist 1004 and the planar joists 1012. As seen in the righthand side of FIG. 12D, the hanger side wall stud 1040 is shown with the protrusion of the lower shoulder end 1041 extending adjacent and parallel to the floor joist 1012 with adjacent flat portions overlaying the hanger joist 1004 (normal to the viewer, in this view) and additionally overlaying the floor joist 1012 along its length.

[0207] Referring now to FIG. 12E, a joint formed at the intersections of the hanger joist 1004, planar joists 1012, outer corner stud 1060 and hanger side corner stud 1050 is shown. In the centermost portion of FIG. 12E, the planar joists 1012 extend normally relative to the viewer. The outer corner stud 1060 and hanger side corner stud 1050 are coupled to the planar joists 1012 via the lower shoulder ends 1061, 1051, respectively. The protrusions of the lower shoulder ends extend downwardly and parallel to the planar joists 1012, with the flat shoulder portion of the outer corner stud 1060 overlaying the outer planar joist 1012 and52FH13073853.5MTV-25225 the flat shoulder portion of the hanger side corner stud 1050 overlaying the inner planar joist 1012.

[0208] Referring now to FIG. 12F, a joint formed at the intersection of the upper ends of the hanger side wall stud 1040, outer corner stud 1060 and roof joist 704 is shown. A cross-sectional view is shown in the centermost portion of FIG. 12F. Roof joist 704 may be interspaced between the upper rectilinear end 1052 of the hanger side wall stud 1050 and the upper rectilinear end 1062 of the outer corner stud 1060. Roof joist 704 may extend parallel with the outer corner stud 1060 and the hanger side wall stud 1050, such that the widest faces of each stud and the planar surface of the roof joist 704 are in contact. In various embodiments, mechanical fasteners may be used to couple the roof joist 704 to the outer corner stud 1060 and hanger side wall stud 1040. In various embodiments, a mechanical fastener may be emplaced through each of the two studs and the roof joist, or separate mechanical fasteners may be used to couple a single stud to a first side of the roof joist 704 and the second stud to a second side of the roof joist 704.

[0209] Referring now to FIG. 13, a structure 1200 constructed from prefabricated structural elements as described herein is shown. An interlocked web 1020 forming the floor of a structure can be established level with a floor, such as the floor of a building, a footing, foundation or the like. As shown in FIG. 12D, hanger joist 1004 is shown at a frontmost portion of the interlocked web 1020, with the planar joists 1012 extending normally therefrom. The hanger joist 1004 and planar joists 1012 provide for joints at their intersection for the addition of hanger side wall studs 1040 distributed along the hanger joist 1004 as shown in FIG. 12D. Hanger side wall studs 1040 may establish an outer side wall of the structure 1200. Each hanger side wall stud 1040 may be affixed to the hanger joist 1004 and planar joists 1012 as shown in FIG. 12D. Further, outer corner stud 1060 is shown matingly53FH13073853.5MTV-25225 engaged between the two outermost planar joists 1012, forming a corner of the structure 1200, the joint for which is shown in FIG. 12E.

[0210] In various embodiments, the interlocked web 1020, which may form the floor of the structure 1200, may have a subfloor (e.g., plywood) installed to the top chords of the planar joists 1012 that extend along structure. End side wall studs 1030 may together, form an adjacent wall to the wall formed by the hanger side wall studs 1040. In various embodiments, structure 1200 may include two wall types, each oppositely positioned about the interlocked web 1020, having similar wall stud types in each opposite wall. That is to say, a first pair of opposite walls may be formed by end side wall studs 1030, and a second pair of opposite walls may be formed by hanger side walls studs 1040.

[0211] In various embodiments, roof joists 704 are can extend across the structure 1200 from a first hanger side wall stud 1040 to a second hanger side wall stud 1040 on opposite sides of the structure, the joint for which can be seen in FIG. 12G. In various embodiments, multiple distinct roof joists 704 may be implemented in the structure 1200, each spaced from one another and extending parallel. The last roof joist 704, (i.e., the two roof joists 704 disposed at the two opposite ends of the structure 1200 may be retained by a series of end side wall studs 1030 having the upper forked ends 1032, shown and described in reference to FIGS. 11 A and 11C. Further, in FIG. 13, the two end roof joists 704, the same roof joists retained by the end side wall studs 1030, may be affixed in the corners of the structure 1200 by the hanger side corner stud 1050 and outer corner studs 1060 at each of the four corners of the structure 1200, as shown and described in reference to FIGS. 12E and 12F.

[0212] Referring now to FIG. 14, an exemplary tool path 1408 for an extruder of an additive manufacturing machine to produce a prefabricated structural element, such as the depicted truss, is shown. The main lines 1409 denote the path that the tool follows, with short54FH13073853.5MTV-25225 segments 1410 in the lower left hand corner denoting forward tip wipe at the end of the bead, and the slanted segment 1411 extending downward and rightward representing travel of the extruder tip to and from the bead path. In various embodiments, the code may begin with a brief purge to remove material that potentially has been sitting in the barrel. The extruder may then perform a startup procedure, slowing the feed rate down to allow material to extrude from the nozzle to not leave a gap of less material in the part and quickly after the feed rate goes to full speed. At the end of each bead there is a tip wipe to prevent the extruder from pulling the bead up as it moves to the next bead. The notched truss design shown may be a two bead per layer print, with each layer taking approximately two minutes and 40 seconds, for an overall print time of approximately 13 minutes and 30 seconds, including the initial purge.

[0213] The reinforced node 1404 shown in FIG. 14, may be formed by make a first pass with an extruder or other additive manufacturing process to form a notched portion extend or coextensive with the outer bead of the frame, then on a subsequent pass, a corner is printed that bonds with the previously printed notch to form a thicker node between the internal members and the outer perimeter of the frame via the notched reinforced node 1404. The reinforced node 1404 allows for greater surface area for welding the separate (or continuous) beads together.

[0214] The tool path shown in FIG. 14 may be followed by an extruder tip of an additive manufacturing machine to print a layer of a truss. In various embodiments, the machine may be configured to manufacture each truss with a length of 92 in, a height of 13 in, and thickness of one in; the 92 in length may be selected to fit the truss on an eight ft long board of homasote, which may be used as the build plate. The start-up part of the print is included to ensure that there is good quality at the beginning of the print, without it the extruder takes time to push material out, leaving a gap or area of poor quality. In various55FH13073853.5MTV-25225 embodiments, each truss, depending on the design, configuration of various segments, and material utilized, among other factors, may be produced in 13 minutes 30 seconds, weighing 13 lbs., for a material deposition rate of - 60 lb. / hr. The layer return time for each truss is roughly 2 minutes and 40 seconds, which is long enough to not require a dwell period to ensure that the previous layer is stiff enough to hold the load of the layer being deposited.

[0215] While the disclosed subject matter is described herein in terms of certain preferred embodiments, those skilled in the art will recognize that various modifications and improvements may be made to the disclosed subject matter without departing from the scope thereof. Moreover, although individual features of one embodiment of the disclosed subject matter may be discussed herein or shown in the drawings of the one embodiment and not in other embodiments, it should be apparent that individual features of one embodiment may be combined with one or more features of another embodiment or features from a plurality of embodiments.

[0216] In addition to the specific embodiments claimed below, the disclosed subject matter is also directed to other embodiments having any other possible combination of the dependent features claimed below and those disclosed above. As such, the particular features presented in the dependent claims and disclosed above can be combined with each other in other manners within the scope of the disclosed subject matter such that the disclosed subject matter should be recognized as also specifically directed to other embodiments having any other possible combinations. Thus, the foregoing description of specific embodiments of the disclosed subject matter has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosed subject matter to those embodiments disclosed.

[0217] It will be apparent to those skilled in the art that various modifications and variations can be made in the method and system of the disclosed subject matter without56FH13073853.5MTV-25225 departing from the spirit or scope of the disclosed subject matter. Thus, it is intended that the disclosed subject matter include modifications and variations that are within the scope of the appended claims and their equivalents.57FH13073853.5

Claims

MTV-25225CLAIMSWhat is claimed is:

1. A system for prefabricated structural elements, the system comprising: a set of first trusses positioned parallel to one another and a first axis, wherein each first truss extends between a first proximal end and a first distal end, and comprises a top edge having a plurality of first notches positioned between the first proximal end to the first distal end; a bottom edge spaced from the top edge; and a plurality of internal members extending from the top edge to the bottom edge to form a planar rigid frame; a set of second trusses positioned parallel to one another and perpendicular to the set of first trusses, wherein each second truss extends between a second proximal end and a second distal end, and comprises a top edge; a bottom edge having a plurality of complementary notches formed therein; a plurality of internal members extending from the top edge to the bottom edge to form a planar rigid frame; wherein each one of the plurality of first notches is shaped to receive and engage with a respective corresponding one of the plurality of complementary notches thereby forming an interlocking web.

2. The system of claim 1, wherein the first trusses and the second trusses are additively manufactured.

3. The system of claim 1 or 2, wherein the first trusses and the second trusses are formed from a plastic material or a fiber-reinforced plastic material.58FH13073853.5MTV-252254. The system of claim 1 or 2, wherein the first trusses and the second trusses are formed from a composite material.

5. The system of claim 1 or 2, wherein the first trusses and the second trusses comprise acrylonitrile butadiene styrene (ABS) having carbon fiber filaments embedded therein.

6. The system of claim 1 or 2, wherein the first trusses and second trusses are formed from a metal material.

7. The system of claim 1 or 2, wherein the first trusses and the second trusses are formed from a recycled material.

8. The system of claim 1 or 2, wherein the top edges of the first trusses and the second trusses are positioned in a plane to form the interlocking web having a planar top surface.

9. The system of claim 1 or 2, wherein each first proximal end is positioned at a first elevation, and each first distal end is positioned at a second elevation, wherein the second elevation is below the first elevation, and wherein each second truss is regularly positioned between the first elevation and the second elevation, thereby forming a ramped interlocking web.

10. The system of claim 9, wherein the plurality of second trusses are oriented at an oblique angle relative to the plurality of first trusses.

11. A system of prefabricated structural elements, the system comprising: a plurality of stringers extending parallel to one another, each stringer having: an inclined top chord extending between a first proximal end and a first distal end, the top chord defining a plurality of stepped surfaces descending from the first proximal end to the first distal end,59FH13073853.5MTV-25225 a plurality of first notches disposed along the plurality of stepped surfaces; an inclined bottom chord spaced from the inclined top chord and extending between the first proximal end and the first distal end; a plurality of internal members extending between the top chord and the bottom chord forming a trussed joist frame; a plurality of treads positioned along the plurality of stringers, each tread extending perpendicular to the plurality of stringers, each tread comprising: a top edge extending between a second proximal end and a second distal end; a bottom edge spaced from the top edge; a plurality of internal members extending between the top edge and the bottom edge forming a truss; a plurality of complementary notches disposed along the bottom edge; and wherein each one of the plurality of first notches is shaped to receive and engage with a respective corresponding one of the plurality of complementary notches thereby forming an interlocking web wherein respective top edges of the stringers are aligned with the plurality of stepped surfaces along the top chord.

12. The system of claim 11, wherein each stepped surface comprises two complementary notches.

13. The system of claim 12, wherein a first complementary notch is disposed at a proximal edge of a respective stepped surface and a second complementary notch is disposed at a distal edge of the respective stepped surface.

14. The system of any one of claims 11-13, wherein each of the treads is oriented at an oblique angle relative to the plurality of stringers.60FH13073853.5MTV-2522515 The system of claim 11, wherein each of the stringers and each of the treads are additively manufactured.

16. The system of claim 11, wherein each of the stringers and each of the treads are formed from a plastic material or a fiber-reinforced plastic material.

17. The system of claim 11, wherein each of the stringers and each of the treads are formed from a composite material.

18. The system of claim 11, wherein each of the stringers and each of the treads comprise acrylonitrile butadiene styrene (ABS) having carbon fiber filaments embedded therein.

19. The system of claim 11, wherein each of the stringers and each of the treads are formed from a metal material.

20. The system of claim 11, wherein each of the stringers and each of the treads is formed from a recycled material.

21. A system of prefabricated structural elements, the system comprising: at least one first planar truss having: a first perimeter delimiting the at least one first planar truss; at least one internal member spanning the first perimeter; wherein the at least one first planar truss is additively manufactured.

22. The system of claim 1, wherein the at least one first planar truss comprises a geometric feature configured to receive and matingly engage with at least one other structural component.61FH13073853.5MTV-2522523. The system of claim 22, wherein the at least one structural component comprises at least one second planar truss.

24. The system of claim 23, wherein the at least one second planar truss comprises: a second perimeter delimiting the at least one second planar truss; and at least one internal member spanning the second perimeter; wherein the at least one second planar truss is additively manufactured.

25. The system of claim 24, wherein the at least one second planar truss comprises a geometric feature configured to receive and matingly engage with the at least one first planar truss or the structural component.

26. The system of claim 24, further comprising a plurality of second planar trusses, each comprising at least one geometric feature configured to matingly engage with the at least one other of the second planar trusses.

27. The system of claim 26, wherein the geometric feature comprises at least one notch formed in the first perimeter or the second perimeter.

28. The system of claim 27, wherein the geometric feature comprises a shoulder.

29. The system of claim 27, wherein the geometric feature comprises a slotted feature.

30. The system of claim 25, wherein the at least one first planar truss and the at least one second planar truss interlock to form a structural web.

31. The system of claim 24, wherein the first perimeter and the second perimeter are substantially rectilinear.62FH13073853.5MTV-2522532. The system of claim 30, wherein the at least one planar truss comprises a protrusion, and the at least one second planar truss comprises a slotted feature, and the protrusion is configured to matingly engage with the slotted feature.

33. The system of claim 24, wherein the first perimeter and the second perimeter are substantially triangular.

34. The system of claims 33, wherein the first planar truss or the at least one second planar truss is formed as one selected from the group of: a kingpost, a fink, double fink, dual pitch, inverted, queenpost, modified queenpost, gambrel, piggyback, hip, Polynesian, studio, howe, double howe, scissors, attic, cathedral, fan, monopitch, bowstring, flat, sloping flat, cambered or stub roof joist.

35. The system of claim 30, wherein the first planar truss and the at least one second planar truss are coupled at an angle.

36. The system of claim 24, wherein at least a portion of the at least one first planar truss and the at least one second truss are formed from one selected from a group of: a plastic material, a fiber-reinforced plastic material, a composite material, or a metal material.

37. The system of claim 36, wherein the at least one first truss and the at least one second truss comprise acrylonitrile butadiene styrene (ABS) having carbon fiber filaments embedded therein.

38. The system of claim 36, wherein the at least one first truss and the at least one second truss comprise recycled polyethylene terephthalate (rPET).

39. A system of prefabricated structural elements, the system comprising:63FH13073853.5MTV-25225 a first hanger joist and a second hanger joist spaced apart and extending parallel to one another, each having a top chord spaced from a bottom chord with a plurality of internal members extending therebetween, wherein the plurality of internal members form a plurality of opposite and opposing slots; at least one planar joist extending from a proximal end to a distal end, the at least one planar joist having a top chord spaced from a bottom chord with a plurality of internal members extending between the top chord to the bottom chord; wherein the at least one planar joist extends perpendicularly between the first and the second hanger joists, and is configured to engage with one of the plurality of slots of the first hanger joist at the proximal end and engage with one of the plurality of slots of the second hanger joist at the distal end to form an interlocked web structure.

40. The system of claim 39, wherein the at least one planar joist comprises a plurality of reinforced nodes disposed at points where the plurality of internal members contact the bottom chord.

41. The system of claim 39, comprising a plurality of parallel planar joists spaced from one another, each of the plurality of planar joists configured to engage with a respective one of the plurality of slots of the first and the second hanger joists at respective distal and proximal ends.

42. The system of claim 41, wherein the top chords of the plurality of planar joists and the first and the second hanger joists are coplanar.

43. The system of claim 41, wherein a first portion of the plurality of planar joists has a first thickness, and a second portion of the plurality of planar joists has a second thickness.64FH13073853.5MTV-2522544. The system of claim 39, further comprising at least one pile configured to engage with the bottom chord of at least one of the first or the second hanger joists.

45. The system of claim 44, wherein the at least one pile comprises an upper forked end, forming a central notch between opposite upwardly extending protrusions, the central notch configured to receive the bottom chord of the first or the second hanger joist.

46. The system of claim 44, wherein a first pair of piles is configured to receive the first hanger joist and a second pair of piles is configured to receive the second hanger joist.

47. The system of claim 39, further comprising a plurality of end side wall studs, each end side wall stud having an elongate body having a lower shoulder end opposite an upper forked end.

48. The system of claim 47, wherein each of the plurality of end side wall studs is configured to engage with the top chord of at least one planar joists at the lower shoulder end and configured to engage with a roof joist at the upper forked end.

49. The system of claim 39, further comprising a plurality of hanger side wall studs, each hanger side wall stud having an elongate body having a lower shoulder end opposite an upper shoulder end.

50. The system of claim 49, wherein each of the plurality of hanger side wall studs is configured to engage with the top chord of at least one hanger joist and at least one planar joist at the lower shoulder end and configured to engage with a roof joist at the upper shoulder end.65FH13073853.5MTV-2522551. The system of claim 39, further comprising a plurality of outer corner studs, wherein each of the outer corner studs has an elongate body with a lower shoulder end opposite a rectilinear end.

52. The system of claim 51, wherein each of the outer corner studs is configured to engage with a terminal one of the plurality of planar joists at the lower shoulder end and configured to engage with a roof joist at the rectilinear end.

53. The system of claim 39, further comprising a plurality of hanger side corner studs, wherein each of the hanger side corner studs has an elongate body with a lower shoulder end opposite an upper rectilinear end.

54. The system of claim 53, wherein each of the hanger side corner studs is configured to engage with at least one hanger joist and at least one planar joist at the lower shoulder end, and to engage with a roof joist at the upper rectilinear end.

55. The system of any one of claims 39-54, wherein at least a portion of the prefabricated structural elements are additively manufactured.

56. The system of claim 39, wherein the prefabricated structural elements are formed from a recycled polyethylene terephthalate (rPET).

57. The system of one of claims 39, wherein at least a portion of the prefabricated structural elements are formed from at least one of a plastic material, a fiber-reinforced plastic material, a composite material, or a metal material.66FH13073853.5

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