Novel additively manufactured connections for cold-formed steel construction: FE investigation

Within this study a hybrid lightweight steel framing (LSF) system is developed, integrating novel additively manufactured (AM) connections utilising wire and arc additive manufacturing (WAAM) and laser metal deposition (LMD). By means of validated finite element studies, the gravity and pushover response of the developed AM-LSF system is investigated and compared to that of conventional LSF systems. AM connections comprise multiple tooth wheel-shaped connectors printed on the LSF joist and stud members, creating an interlocking mechanism. The results indicate comparable gravity and pushover performance of the AM-LSF with that of the conventional LSF. A combined joist–stud–wheel yielding and local buckling of the joist around the wheel region is identified as the governing limit state, depending on the AM connection configurations, which affects the gravity and pushover performance of the frames. AM connection prototyping reveals practicality aspects of both WAAM and LMD printing methods. Beyond structural performance, the proposed AM-LSF system offers practical benefits including reduced on-site labour, faster construction, and potential for reuse and sustainable construction.