Carbon Coupler

This coupler acts as a sleeve to connect the two sticks of lumber back to a single configuration for construction in the building. The coupler offers a stronger connection than a fastener connection without the utilization of fasteners or the risk of damage to the lumber. To achieve this solid connection, gravity, compression, and tight fitment secure and ensure the sticks are secured in position.

The coupler is made from carbon fiber using a combination of robotic extrusion and 3D printing technologies. It features one or more openings to accommodate the lumber, which is prepared with a taper for a secure fit. The carbon fiber is extruded vertically, layer by layer, and heated to a specific temperature to ensure a solid bond between layers, resulting in a durable coupler.

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The design of the Carbon Coupler ensures a tight fit and correct placement of the timber, with the added benefit of being disassemblable. The process involves inserting the tapered wood into the coupler's cavity, where it is held firmly in place, facilitating the construction of various structures.

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Further design enhancements include modifications to the coupler's axis, introducing rotational capabilities and structural complexity through spirals or elbows. The addition of ribs to the design not only increases the coupler's strength but also allows for branching configurations, supporting more complex architectural designs.

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The Carbon Coupler project highlights the potential of new materials and manufacturing methods to improve construction practices, offering a practical solution for enhancing the structural integrity of wood-based constructions.