New Opportunities for Optimizing Structural Elements - Salomé Galjard, Arup

In a research project that started several years ago, Arup has experimented with the possibilities of Additive Manufacturing (AM) and potential applications of this technique in the Building Industry. Initial results of a printed structural node, released in 2014, were the first of its kind and attracted global attention which boosted the interest in and acceptation of this technique in our sector.

Arup is continuing the research, sharing our growing knowledge of and insights on design freedom, but also restrictions, possible savings and costs, do’s and don’ts. Our goal is to add Additive Manufacturing to the range of solutions we use on our projects. We believe that broadening that range will result in the most efficient, durable and beautiful designs. We also hope to inspire our partners and clients to use AM to their best advantage in their work and we believe this can have a positive and lasting influence on the world we live in.

The presentation will focus on the design process of the structural nodes, but will also illustrate our insights, struggles and general enthusiasm about this fascinating new opportunity.

Transcript

1. New Opportunities for Optimizing Structural Elements in Metal by Using Additive Manufacturing // Salomé Galjaard
2. © Studio i2
4. / / additive manufacturing Additive Manufacturing © DMRC A process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies, such as traditional machining (ASTM). SLS / / DMLS / / SLM
5. / / other sectors Additive Manufacturing aviation (fuel nozzle) aerospace (venturi nozzle) automotive (race car knuckle) © GE © Morris Technologies, Inc. © EOS
6. / / optimization for function 109kN Additive Manufacturing
7. / / optimization for function Additive Manufacturing
8. / / optimization for function Additive Manufacturing
9. / / optimization for production Additive Manufacturing
10. / / optimization for production Additive Manufacturing
11. / / optimization for production Additive Manufacturing
12. / / production Additive Manufacturing
13. / / product before & after Additive Manufacturing
14. / / the second iteration Additive Manufacturing Pin & fork connections and spanner eliminated
15. / / influence on the structure Additive Manufacturing struts cables nodes 50% lighter compression & tension 20% less
16. / / optimization for function Additive Manufacturing
17. / / optimization for function Additive Manufacturing
18. / / optimization for function Additive Manufacturing
19. / / optimization for production Additive Manufacturing
23. / / structural comparison Additive Manufacturing Stainless steel 316L Galvanised S355 steel Maraging steel 1.2709 Von Mises stresses (MPa)
24. / / material test Additive Manufacturing From the tests performed, the mechanical properties achieved were largely in accordance with normal wrought product forms, such as bars, plates, sheets and tubes in the solution annealed and mildly cold worked conditions. All of the test results conformed to the requirements of relevant international product standards for comparative products, with subtle variations in typical composition and mechanical properties. The results were very encouraging in the context of the project and demonstrate that current selective laser melting techniques, applied to suitable materials present a valid technology for the production of components of satisfactory quality and integrity. As Printed 100x Annealed 1050°C 100x
25. / / thank you