RigidCore is a structural technology company. The gyroid composite beam — USPTO Patent Pending #63/991,057 — is the core invention. The CNC machine line is its first commercial proof. One structural system. Multiple industries.
The gyroid is a triply periodic minimal surface — a geometry found in nature that distributes stress more efficiently than any conventional structural form. Applied to composite manufacturing, it produces a beam with superior stiffness-to-weight, better vibration damping, and thermal stability that welded steel cannot match. That beam is the foundation of every RigidCore product.
Proven under continuous cutting forces
USPTO #63/991,057 · Filed Feb 25, 2026
CNC · Construction · Robotics · Aerospace
The gyroid composite beam is not a single material — it is an engineered system. Each layer serves a distinct mechanical function. Together they produce stiffness-to-weight and vibration damping that welded steel cannot approach at any mass.
Structural skin with lattice windows — counter-bored through-holes that allow the composite matrix to mechanically interlock with the exterior, eliminating delamination under continuous vibration.
Patent-pending epoxy rivets sized 5 mm to 15 mm based on FEA-identified stress gradients. Larger near the spindle load zone. Smaller in low-stress regions. Strength where it is needed.
A longitudinal array of carbon fiber and glass-reinforced plastic tubes. Outer perimeter tubes carry bending loads in tension and compression. Inner tubes carry constrained damping material.
Tube diameter and wall thickness vary by position — smaller at the perimeter for maximum skin bonding surface area, larger at the core for mass damping. Tunable to any spindle load profile.
High-temperature polymer ribs maintain tube geometry during infusion and act as integrated flow channels — allowing controlled resin distribution and cooling fluid routing during cure.
High-tensile rods run the full beam length and are torqued after cure. This places the composite core in active compression — neutralizing spindle deflection before it reaches the tool tip.
Tubes are selectively filled with damping media tuned to specific frequency targets. The result is a beam that absorbs vibration across a broad spectrum rather than ringing at a single resonant frequency.
Performance figures are design targets derived from FEA simulation. Certified test data will be published following prototype validation. USPTO Patent Pending #63/991,057.
The most demanding test for a structural beam is a precision machine tool. Continuous vibration. Thermal cycling. Cutting forces that never stop. If the gyroid composite beam holds micron-level tolerances in that environment, its performance in construction, robotics, and aerospace is not a question — it is a proof.
From the 36″ Maker to the 14-foot Industrial — every frame built on the gyroid composite beam. →
The gyroid composite beam that makes every RigidCore machine rigid enough to hold tolerance is the same structure that outperforms welded steel in construction, aerospace, and robotics applications. The CNC machine line is the first proof. The structural system is the product.
Proven under worst-case conditions — continuous vibration, thermal cycling, cutting forces. RC-4040 through RC-5168.
Superior stiffness-to-weight. Better vibration damping. Patent-pending geometry manufacturable at scale. In development.
Arm assemblies, end effectors, chassis frames. Lower mass means faster movement and less motor torque. Connects to RigidRobotics platform. In development.
Secondary structures, brackets, and frames where stiffness-to-weight is the primary design constraint. In development.
For industries where direct manufacturing is not the right path, the RigidCore structural system is available for licensing through RigidRoyalty. The licensee manufactures. KI collects royalties. The geometry stays protected.
Licensing inquiries →RigidCore is the structural foundation. Every other pillar exists to make it smarter, faster, and more sovereign.
Kavanagh Industries · Always on