Computational design for the wire and arc additive manufacturing process

The world has seen industrial revolutions with advancements in manufacturing technologies. The advancements in Additive Manufacturing (AM) technologies will bring another revolution sooner rather than later. Nowadays, the Wire and Arc Additive Manufacturing (WAAM) process is already used to manufacture large-scale structures such as ship...

Bringing Glass Giants to life: Fabrication of mass-optimized structural glass components of complex form

Current research conducted at TU Delft focused on utilizing structural Topology Optimization (TO) for designing large monolithic cast glass structures with maximum stiffness and minimum mass. These structures demonstrated improved manufacturability in terms of time, energy, and cost efficiency due to their mass efficiency, which results in...

Printing Reinforcement Steel: A study towards optimised, additive manufactured steel for reinforced concrete

In light of the global attempts to reduce material use by the construction industry, this research focuses on combining topology optimisation with additive manufacturing of steel. It is investigated whether an automated procedure can be developed to generate reliable strut and tie models for reinforced concrete elements, while satisfying the...

Design and optimisation of an additively manufactured patient-specific partial mandible reconstruction implant

Additive manufacturing (AM) provides the opportunity for complex porous designs, without the costs depending on batch size. Therefore patient-specific implants can be rapidly manufactured. In clinical practice, reconstruction of the mandible is needed in case of bone tumors or trauma. Part of the mandible is removed and the shape of the missing...

Shaping transparent sand in sand: Fabricating topologically optimised cast glass column using sand moulds

This research investigates the potential of 3D printed sand moulds for casting structural glass column having optimised cross section. Conventionally, Glass, in architectural industry, has been used in form of sheets (Float glass) due to ease of fabrication of planar sheets, but in last few years, cast glass bricks have been used for creating...

Overhang constraint in topology optimisation for additive manufacturing: A density gradient based approach

This research aims at improving the synergy between 3D printing and topology optimisation. 3D printing, more formally known as additive manufacturing, forms an object by constructing successive layers on top of each other. This procedure of manufacturing offers new possibilities due to the improved design freedom. Topology optimisation is a...