Fatigue Stress Concentration Factor Reduction via Metal Additive Manufacturing

This paper examines the potential of using additive manufacturing (AM) technology to create nature-inspired designs with decreased stress concentration factors, which are typically the source of fatigue damage. AM has advantages over conventional manufacturing processes, allowing for creation of complex and optimized geometries. Based on a real case study, this paper evaluates the possibility of bio-inspired optimization of a connection between a tubular profile and a steel plate through AM technology. The results reveal a significant decrease in the stress concentration factor for the optimized bio-inspired AM solution compared to traditional construction solutions.