“One of the Holy Grails of composites manufacturing is a robust, consistent, automated fabrication process that makes possible the kinds of high-volume, high-quality applications that have, for much of the industry’s history, been out of reach.”
Wood’s strength comes from its grain, composed of long, aligned fibers that run parallel to the tree’s growth. This natural alignment gives wood its structural integrity and exceptional resistance, especially when force is applied along the grain.
Biomimicry Is Badass
Inspired by this concept, ARRIS developed the category-defining Additive Molding technology in 2017, revolutionizing the way advanced composites are designed and manufactured.
Additive Molding by ARRIS is the only technology platform in the world that enables this kind of cutting-edge composites.
Ideal Material Efficiency
All is made possible because the tech stack includes proprietary design software, materials, and high-volume manufacturing system.
At ARRIS, domain experts leverage robotics, automation, materials, engineering, and software development to engineer award-winning, breakthrough products that push boundaries.
From Traditional Weave To 3D-Aligned Continuous Fiber
A New Era of Carbon Fiber Composites
The ARRIS approach surpasses traditional woven carbon fiber by precisely aligning fibers where needed, resulting in lighter, higher-performing parts while using significantly less material and producing less waste. Unlike the weave method, which also relies on unrecyclable plastics, ARRIS utilizes reusable thermoplastics to create novel, high-performance designs for modern applications.
ARRIS® EARNEDRANK AS #4 on Fast Company's Top 10 Most Innovative Manufacturing Companies
Unmatched Performance
First-of-Its-Kind Continuous Fiber-Reinforced Thermoplastic Composites Technology with Highest Performance Advantages ( Yikes, That's a Mouthful)
Lightest Strength-To-Weight Ratio
State-of-the-Art Carbon Fiber Composites Are Pretty Good, But ARRIS Took It a Step (or Two) Further In Pursuit of Greatness
Unique Like Fingerprints
Each Part Is Originally Different By Way of Fiber Flow Similar To Tree Grain, Yet The Structure Consistently Performs The Same
Practical Results
200,000+ Propulsion Plates Made with ARRIS® Technology for Elite Performance Running Shoes... And, That's Just Footwear
Greater Sustainability
Tech Cuts Emissions, Uses Recyclable Bio-Based Thermoplastic Materials & Significantly Reduces Waste vs. Commonly Used Composites
Award-Winning Team
8x Award Recipient as a Category Creator in Advanced Manufacturing for Unprecedented Software, Material & Process Innovation
The ARRIS® team starts by producing its own materials, creating a filament made of thermoplastic resin and continuous fibers. This filament is then shaped using a process similar to wire bending, much like how a spring or coat hanger is formed.
3D stress-aligned fibers optimize strength & stiffness
These wire-like shapes are then placed into a custom mold, where heat and pressure are applied to compress, shape, and further strengthen the part into its final form. Pretty cool, right?
But let's not forget the proprietary software stack that's a big part of the ARRIS® Technology.
Topology-optimized, material-efficient structures
Check out a podcast interview on how composites manufacturing impacts marathon running to learn more... LISTEN >
I’m a cyclist, so carbon fiber is almost part of my being. So when I first heard about Brooks Sports teaming up with composites gurus ARRIS to develop a breakthrough new running shoe with a carbon fiber plate in its sole, I knew I had to learn more.
— Jim Vinoski, Manufacturing ContribuorApril 2023: "At The Boston Marathon, The Arris-Brooks Partnership Will Test A New Cutting-Edge Shoe"
Thermoplastic might be the word of the year, or the decade, in the industry, with several companies in and out of the industry bringing the technology to the bike world. Compared to the more common thermoset layup carbon fiber used in the industry, thermoplastic fabrication promises to be more efficient, with less waste and lower environmental impact.
— Stephen FrothinghamApril 2024: "Arris brings thermoplastic technology to spokes and components"
The ARRIS plate used in these Brooks super shoes isn’t just any carbon fiber plate, it’s a unique composite that offers significant benefits over more traditional carbon plates commonly used in high-end running shoes.
— Helen, Co-Founder & WriterTrail & Kale, The Next-Level ARRIS Carbon Fiber Plate Behind Brooks’ HE4 Super Shoe
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