Conference Paper: Peer Reviewed

Challenges of Scale in Modelling Material Behaviour of Additive-Manufactured Nodes

by Williams N., Crolla K, Prohasky D., Burry J., Leary M, Brandt M., Xie M. and Seifi H.

ABSTRACT | The application of Additive Manufacturing (AM) technologies promises much innovation across the manufacturing sector, and has generated great interest in the Architecture, Engineering and Construction (AEC) industry. This paper presents and reflects upon early prototypes for integrating AM in a construction application, through the design of a prototype frame structure with linear members connected by nodes of unique shapes. As an enabler for design, a system is developed and implemented to integrate expertise across architecture, structural engineering and advanced manufacturing in order to design and detail components for single layer canopies. This includes the topology optimisation and additive manufacture of nodes, both of which require the control of material behaviour at small scales. A scaled pavilion structure and full-scale node prototypes were successfully realised. However, this first stage of research presented a number of challenges to modelling material behaviour across scales—both the physical size and production volumes.

KEYWORDS | Topology Optimisation; Additive Manufacture; Selective Laser Melting; Fuse Deposition Modelling; Tensegrity Structure

CITATION | Williams Nicholas, Crolla Kristof, Prohasky Daniel, Burry Jane, Leary Martin, Brandt Milan, Xie Mike, and Seifi Hamed. “Challenges of Scale in Modelling Material Behaviour of Additive-Manufactured Nodes”. Paper presented in the Modelling Behaviour – Design Modelling Symposium Copenhagen 2015, organized by Design Modelling Symposium Copenhagen 2015, 7 pgs. Copenhagen, Denmark