For this thesis an additively manufactured(AM) glass connection was researched. The aim was to see if it was possible to use plastic based AM for end use parts in the façade. This was done in three parts, which are presented in this thesis. The first part consists of research in all currently available technology that could be used to create such a connection. The following section is about the design process of the AM connection and its engineering. The final part of the research further validates the design by means of structural tests and a rough price comparison to already existing glass connections.

The first part of this research focused on glass connections, additive manufacturing and topology optimization. This was primarily literature research that gave insight into which existing bases could be used to build on further in this project. The research showed that the spider profile has the most potential for further development and become a new sort of connection. The research also provided insight in the different AM technology’s that could make the new connection. That research was necessary to selected the final production method an used materials. In the final part of the literature study insight in topology optimization was obtained to design the connection with the help of topology optimization.

The findings from the first part of the research provided the basis for the design and engineering processes of this new AM glass connection. The connection was designed with the help of topology optimization. The idea behind the optimization was to reduce the stresses in the glass and to attach the connection to the glass without drilling. The result of the optimization was a connection that has the shape of a line and that would be bonded to the glass with Transparant Silicone Structural Adhesive better known as TSSA. This connection consists of a number of different elements. The first is a separate AM piece that would be laminated to the glass and could be inserted into the remainder of the joint that connects four corners of four different glass plates. The second element is adapted to allow for the free movement of the glass panels by locally removing material so it would be weaker in one direction. Alternatively, it is given a power joint, which is a rubber joint that allows for movement in all directions. This connection was calculated multiple times to see how the connection would perform.

In the final part of this thesis the joint itself was researched to further validate the connection. This was done by making a prototype of the connection to see how everything could work and if it was actually suitable for production. For this validation, process a number of tests were done on smaller specimens to show how strong the material is and to give validation to the calculations. Finally, a small study was done in to the market potential of custom glass connections like this one by making price comparisnos to currently existing spider profiles.