Custom Truss Top Plate

AGAM was recently approached by a client for a booth design consisting of our truss system. Our system is composed of several key parts including the truss itself, the endplate for the sides of each truss, and the top plate that supports the truss. The top plate is essential to the construction of the truss because it serves as the connection point between the vertical extrusion and the truss. It also controls the angle at which the truss extends outwards from the vertical extrusion. Although this offers a very clean and effective solution to any standard truss system, the current design of the top plate does not allow any further extrusions to be built above an existing truss. Therefore, it is impossible to construct multiple levels of trusses off of a single vertical extrusion. Our client’s truss system, however, asked for exactly this. It was our job to work around our existing products and design a solution that would suit the customer’s needs.

The current top plate consist of four main pieces: two outer plates (which provide space for the endplates to attach), one spacer (which sits in between the outer plates), and one insert block (which is screwed into the underside of the bottom outer plate and fits inside of the vertical extrusion). To secure another vertical extrusion above this top plate, we needed to figure out how to attach another insert block onto the top as well.

The solution we engineered provides a simple and easy way for the client to assemble their truss system. It involves using our laser cutter to create a custom outer plate and spacer, each with an extra set of holes. Instead of having only four holes like the current parts, there are now eight. The extra holes become the connection for the insert block to the top, while still allowing the attachment of the bottom insert block as well. Below is an exploded view demonstrating the new assembly:

The insert blocks are held in place by four screws each that are threaded through the outer plate. The holes in the outer plate are counter sunk to allow the screws to sit flush with the surface to avoid interfering with the spacer. Four bolts are used to hold all of the pieces together securely. The hole placement for these bolts was designed to allocate enough space for the insert block to fit between them while still leaving enough room along the outside for the vertical extrusion to fit over top. This was important because when the part is fully-assembled, the bolts are completely hidden from view.
Here in below is a picture of the final assembly before it was shipped out to the client.

If you have a project requiring trusses and special engineering, please feel free to contact me at

Alexandra Hart
Industrial Designer

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