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

Abstract

Current manufacturing techniques in the construction sector are slow, expensive and constrained in terms of architectural shapes. In other manufacturing sectors (such as automotive and aerospace) the use of automated construction systems significantly improved the safety, speed, quality and complexity of products. To realize real-scale structural elements for construction applications without ideally any geometrical constraints either in size or shape, the most suitable manufacturing solution for metallic elements is a directed energy deposition (DED) process referred to as wire-and-arc additive manufacturing (WAAM). The main advantage of WAAM relies on the possibility to create new shapes and forms following the breakthrough design tools for modern architecture as algorithm-aided design. At the same time, the printed part ensures high structural performances with reduced material use with respect to the conventional solution. The study presents a new approach called “blended” structural optimization, which blends topology optimization with basic principles of structural design and manufacturing constraints proper of WAAM technology, towards the realization of new efficient structural elements. The approach is applied to the case study of a I-type stainless steel beam on a multi-storey frame building. The approach could pave the way towards an efficient use of WAAM process to produce a new generation of structurally optimized elements for construction, with a more conscious use of the optimization tools and an efficient application of metal 3D printing.

Experimental and numerical assessment of the topological optimisation of additively manufactured T‐joints

“…Among them, there is [17] that proposes a framework for developing Optimised Tubular Structures documenting both the optimisation and the manufacturing of the selected model. Another study [18] presents a blended structural optimisation approach, which includes WAAM manufacturing constraints.…”

Three-Dimensional Printing of Structural Members with Shotcrete Technique: Design, Construction, and Future Directions

“…Furthermore, this study explores the multitude of prospects and obstacles that lie ahead for the broader implementation of metal AM in the construction industry. A potential functionally graded AM beam is forming an integral component of a hybrid structure [21].…”

Experimental Application of Robotic Wire-and-Arc Additive Manufacturing Technique for Strengthening the I-Beam Profiles

“…Moreover, it is the metal AM process most suitable for adoption for large-scale components characteristic for the construction industry, as it has few limitations in the shape and size of the printed object [13]. First explorations on WAAM for construction have been studied over the recent years [14,15]. Benefits of AM for construction, to name a few, are primarily customization, the potential of reducing construction time, human error and material consumption, and lastly, the potential contribution to structural strengthening and repair [1,16].…”