Computational design, engineering and manufacturing of a material-efficient 3D printed lattice structure

Abstract

Building with additive manufacturing is an increasingly relevant research topic in the field of Construction 4.0, where designers are seeking higher levels of automation, complexity and precision compared to conventional construction methods. As an answer to the increasing problem of scarcity of resources, the presented research exploits the potential of Fused Deposition Modelling in the production of a lightweight load-responsive cellular lattice structure at the architectural scale. The article offers an extensive insight into the computational processes involved in the design, engineering, analysis, optimization and fabrication of a material-efficient, fully 3D printed, lattice structure. Material, structure and manufacturing features are integrated within the design development in a comprehensive computational workflow. The article presents methods and results while discussing the project as a material-efficient approach to complex structures.

Computational Design and 3D Printing of a Biopolymer Construction System for Freeform Applications

“…This work focuses on using biopolymer as the selected material. In the field of biopolymer printing in architecture recent research such as the work of Naboni, Kunic and Breseghello (2020) on the Trabeculae Pavilion or the work of Duro-Royo et al (2017) on Aquahoja focus on ultralight-weight, detailed and complex structures, while this work concentrates on large scaled, easily modifiable, producible and mountable support structure components. In the field of furniture production LSAM methods of biopolymers or recycled plastics are already used in various design concepts (e.g.…”

Leading-Edge Technologies for Architectural Design: A Comprehensive Review

“…The advent of 3D printing has transcended the realm of prototyping to become a viable method for constructing architectural components. From intricate facades to entire buildings, 3D printing offers unprecedented design freedom and resource efficiency (Talbott, 2006;Cohen, 2019;Niemelä et al, 2019;Leach and Farahi, 2018;Žujovi et al, 2022;Howeidy and Arafat, 2017;Naboni et al, 2020). This section explores the evolution from 3D to 4D and 5D printing, where the fourth dimension introduces time as a variable, and the fifth dimension incorporates cost considerations.…”

Computational Design and Analysis of Shell Topologies driven by Different Microstructural Patterns found in Natural Materials

“…Natural systems adjust the material by adding or removing material according to the degree of stress in the stress zones. (Naboni et al, 2020). Evolutionary Structural Optimization (ESO) is based on the process of producing optimal structures by gradually removing the ineffectively used material from the design domain (Xie and Steven, 1997).…”