Gridshell structure joint optimisation through the use of three-dimensional printing technology

Abstract

In today’s architecture there is an increasing demand for the design of complex structures and forms, using innovative technologies and materials. In order to meet the demands of such challenging structures, engineers are constantly striving to find the best solutions in designing efficient structures in terms of costs, speed of construction and feasibility. Three-dimensional printing (also known as additive manufacturing) may already be a proven technology in the medical, automotive and aviation industries, but is still an emerging technology when it comes to architecture and structural engineering. The aim of this study is to provide an insight into the possibilities and capabilities of threedimensional printing (3DP) with regards to the realisation of manufacturing topology optimised structural joints, with a particular focus on reticulated gridshell structures. Following research into gridshell structures, their structural joints, structural optimisation methods and 3DP techniques, the design of a gridshell structure though form-finding techniques was undertaken, with attention then shifting onto the structure’s joints. Through the use of Finite Element Analysis (FEA), Bi-directional Evolutionary Structural Optimization (BESO) techniques and post processing procedures, this study delves into the capabilities of topology optimisation and how these results could be transformed into a feasible manufacturing opportunity through three-dimensional printing. While importance is given to the results achieved through the topology optimisation (TO) process of the node, this research strives to give a holistic outlook of the whole design procedure up until the preparation for 3DP of the node. Therefore, following a quantitative analysis of the results obtained in the TO process, focus is shifted onto the overall methodology undertaken. Highlighting advantages, limitations and areas for improvement which are evident in the process of implementing the use of three-dimensional printing for the realisation of topology optimised joints for rigid reticulated gridshell structures.