ARRIS Additive Molding Continuous Fiber Composite Parts

ARRIS Composites was founded in 2017 in Berkeley, California, and designs, engineers and manufactures carbon fiber parts for drones, aerospace and defense, cycling and footwear. It addresses the gap between high-performance aligned-fiber composites, traditionally limited to aircraft and supercars, and the volumes and costs of mass-market products.

Its patented Additive Molding process impregnates continuous dry fiber with thermoplastic resin, shapes preforms aligned to the part's 3D stress paths, assembles them with inserts or electronics, and molds the final part in one step. ARRIS makes its own materials from carbon, Kevlar and glass fiber with industrial thermoplastics, and also offers Cross Scale long fiber injection molding and continuous fiber compression molding. Parts are produced and 100% tested in Berkeley and in Taoyuan, Taiwan, for brands in cycling, footwear, drones and defense.

• Additive Molding: patented process molding 3D-aligned continuous fiber preforms into one part.
• Multi-material integration: carbon, Kevlar and glass fiber with thermoplastics, metal inserts and embedded electronics.
• Cross Scale: long fiber injection molding for high-volume parts.
• Continuous fiber compression molding: alternative route for simpler high-strength geometries.
• Cosmetic surfaces: class-A molded surfaces with in-mold texturing and decorative films.
• Dual production sites: Berkeley, California and Taoyuan, Taiwan with 100% part testing.

Footwear factories in Vietnam producing performance running and court shoes could source carbon plates and insoles from ARRIS for global brands. Bicycle assemblers could integrate carbon spokes or suspension linkages, and drone makers could replace cut-laminate arms and machined brackets with consolidated molded parts.

ARRIS consolidates assemblies into single molded parts, for example 18 parts into one per side for prop guards and 17 into one airframe, with consolidated parts up to 40% lighter and 35% lower in price. Parts reach plus or minus 0.1 mm as-molded tolerance with no secondary machining, are half the weight of aluminum at the same stiffness and are fully tested before shipping.

Footwear, cycling and drone brands want lighter, stronger parts at consumer volumes, and thermoplastic composites are favored over thermosets for faster molding and recyclability. Asia hosts much of the global footwear, bicycle and drone supply chain, and ARRIS's Taiwan plant positions it close to manufacturers in Southeast Asia, including Vietnam's large footwear sector.

Founded in 2017; headquarters and US production at 745 Heinz Avenue, Berkeley, California, with volume production in Taoyuan, Taiwan. Holds 35+ US patents and makes and tests 200,000+ parts per month. Received an AFWERX contract in November 2025; partners include Specialized (Roval) and Wilson.