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

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.