An End-to-End Framework for the Additive Manufacture of Optimized Tubular Structures

Abstract

Although additive manufacturing (AM) has been maturing for some years, it has only recently started to capture the interest of the cost-sensitive construction industry. The research presented herein is seeking to integrate AM into the construction sector through the establishment of an automated end-to-end framework for the generation of high-performance AM structures, combining sophisticated optimization techniques with cutting edge AM methods. Trusses of tubular cross-section subjected to different load cases have been selected as the demonstrators of the proposed framework. Optimization studies, featuring numerical layout and geometry optimization techniques, are employed to obtain the topology of the examined structures, accounting for practical and manufacturing constraints. Cross-section optimization is subsequently undertaken, followed by a series of geometric operations for the design of free-form joints connecting the optimized members. Solid models of the optimized designs are then exported for wire arc additive manufacturing (WAAM). Following determination of the optimal printing sequence, the trusses are printed and inspected. The efficiency of the optimized designs has been assessed by means of finite element modelling and compared against equivalent conventional designs. More than 200% increases in efficiency (reflected in the capacity-to-mass ratios) were achieved for all optimized trusses (when compared to their equivalent reference designs), demonstrating the effectiveness of the proposed optimization framework.

Topology Optimization for 3D-Printable Large-Scale Metallic Hollow Structures With Self-Supporting

“…A discrete topology optimization method starts with a ground-structure model and produces optimized truss-like structures. For the stiffness problem, the optimization formula is written as (He et al, 2017;Ye et al, 2021;Zhang et al, 2017)…”

Proceedings of the 27th Conference on Computer Aided Architectural Design Research in Asia (CAADRIA) [Volume 2]

“…A discrete topology optimization method starts with a ground-structure model and produces optimized truss-like structures. For the stiffness problem, the optimization formula is written as Ye et al, 2021;Zhang et al, 2017)…”

Blended structural optimization for wire-and-arc additively manufactured beams

“…Intensive effort in this sense was made by the Dutch company MX3D in collaboration with the research team from Imperial College of London to design and fabricate the world's first 3D printed steel footbridge (see, e.g., [7]). Recently, an automated end-toend framework for the generation of high-performance AM structures was implemented to integrate AM techniques into the construction of optimized members [15].…”