Additive Manufacturing in Construction
AMC TRR 277

Project C 02

3D Structural Puzzle – Numerical Multi Scale Shape and Topology Optimisation Methods to Additively Manufacture Optimal Structures from Optimised Pieces

This project deals with additively manufactured structures considered as large 3D puzzles and multi scale optimization aspects. Based on Vertex Morphing, numerical methods for supporting a holistic, simulation based multi scale optimization tool chain will be developed. The goal is to create optimized individual structural pieces which are assembled to form an overall optimal structure. Additive manufacturing is the ideal mean of greatest potential to combine industrial efficient production with individual design and structural layout. The methods will be developed and tested with prototype products and processes in close cooperation.

Objective

  • 3D structural puzzle
  • Numerical Multi Scale Shape and Topology Optimization Methods to Additively Manufacture Optimal

Structures from optimized pieces

Approach

  • We are working in the larger field of Computational Mechanics spanning the area between mechanics, mathematics, and computer science.
  • We are working on the theory of structural analysis, structural optimisation, numerical methods and computer aided modelling.
  • We are experts in developing finite elements for the structural analysis of beams, plates, shells, membranes and solids.
  • We develop algorithms for non-linear and multiphysical coupled analysis, form finding, and optimisation, as well as their combinations.
  • We develop data models to support the interaction of analysis and computer aided design.
  • We are implementing our methods into own and open-source software, supporting parallel and high-performance computing.
  • We rely on long years’ experience about tight cooperation with other ambitious groups on large software projects, e.g. KRATOS together with CIMNE.

Networking with other projects

We develop numerical optimisation methods as basic digital tools to support additive manufacturing of individually designed structural components. We deliver theory and tools of computational mechanics and numerical structural optimisation to the TRR. If not specifically indicated, we closely cooperate with almost all projects of focus area A (A01-02-03-06-08), and many of focus area C (C01-03-04-05-06). Their needs are the root of methodological development and they will apply the methods we develop. Along that course we will have steady and intense collaboration to define benchmarks for testing or to work on the practical, real size objects of the final, intended use cases (A01-08) and construction processes (C03-06). Already, together we have identified that many of the questions and the structure of collaboration appear to be formally identical.

Project leaders

Dr. Sc. Pierluigi D’Acunto

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Project leader

D’Acunto, Pierluigi Dr. Sc.

is TT-assistant Professor at the Professorship of Structural Design –Technical University of Munich. In his doctoral research the focus is on vector- based 3D graphic statics and design of spatial structures based on the relation between form and forces.

Project(s)

Project C 02

3D Structural Puzzle – Numerical Multi Scale Shape and Topology Optimisation Methods to Additively Manufacture Optimal Structures from Optimised Pieces

Prof. Dr.-Ing. habil. Roland Wüchner

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Project leader

Wüchner, Roland Prof Dr.-Ing.

He has been Head of the Institute of Statics and Dynamics at TU Braunschweig since September 2021.

Project(s)

Project C 02

3D Structural Puzzle – Numerical Multi Scale Shape and Topology Optimisation Methods to Additively Manufacture Optimal Structures from Optimised Pieces

Contributors

M. Sc. Christiane Richter

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Richter, Christiane M. Sc.

Christiane Richter is a research associate and doctoral candidate at the Professorship of Structural Design at the TUM School of Engineering and Design. Under the guidance of Prof. Dr. Pierluigi D’Acunto, she is conducting research within the C02 project. With a solid foundation in structural engineering and expertise in concrete Additive Manufacturing, her primary focus lies in formulating a Holi…

Project(s)

Project C 02

3D Structural Puzzle – Numerical Multi Scale Shape and Topology Optimisation Methods to Additively Manufacture Optimal Structures from Optimised Pieces

Related Publications

Shape optimization of embedded solids using implicit Vertex-Morphing

2024 | M. Meßmer, R. Najian, S. Kollmannsberger, R. Wüchner, K.U. Bletzinger: Shape optimization of embedded solids using implicit Vertex-Morphing, Computer Methods in Applied Mechanics and Engineering, Volume 426, 2024, 116999, ISSN 0045-7825

https://doi.org/10.1016/j.cma.2024.116999

Robust numerical integration of embedded solids described in boundary representation

2024 | M. Meßmer, S. Kollmannsberger, R. Wüchner, K.U. Bletzinger: Robust numerical integration of embedded solids described in boundary representation Computer Methods in Applied Mechanics and Engineering, Volume 419, 2024

Node-Based Shape Optimization and Mechanical Test Validation of Complex Metal Components and Support Structures, Manufactured by Laser Powder Bed Fusion

2023 | A. Ghantasala, J. Diller, A. Geiser, D. Wenzler, D. Siebert, C. Radlbeck, R. Wüchner, M. Mensinger, K.U. Bletzinger: Node-Based Shape Optimization and Mechanical Test Validation of Complex Metal Components and Support Structures, Manufactured by Laser Powder Bed Fusion. In: Trzcielinski, S., Mrugalska, B., Karwowski, W., Rossi, E., Di Nicolantonio, M. (eds) Advances in Manufacturing, Production Management and Process Control. AHFE 2021. Lecture Notes in Networks and Systems, vol 274. Springer, Cham.
https://doi.org/10.1007/978-3-030-80462-6_2

The implicit bulk-surface filtering method for node-based shape optimization and a comparison of explicit and implicit filtering techniques

2023 | R. Najian Asl, K.U. Bletzinger: The implicit bulk-surface filtering method for node-based shape optimization and a comparison of explicit and implicit filtering techniques. In: Structural and Multidisciplinary Optimization 66, 111 (2023).
https://doi.org/10.1007/s00158-023-03548-2

Node-Based Shape Optimization and Mechanical Test Validation of Complex Metal Components and Support Structures, Manufactured by Laser Powder Bed Fusion

2021 | Ghantasala, A.; Diller, J.; Geiser, A.; Wenzler, D.; Siebert, D.; Radlbeck, C.; Wüchner, R.;  Mensinger, M.; Bletzinger, K.U.: Node-Based Shape Optimization and Mechanical Test Validation of Complex Metal Components and Support Structures, Manufactured by Laser Powder Bed Fusion. In: Advances in Manufacturing, Production Management and Process Control. AHFE 2021; Lecture Notes in Networks and Systems, vol 274. Springer, Cham. – DOI: https://doi.org/10.1007/978-3-030-80462-6_2.

More projects of
Focus Area C

Project C 01

Bridging Scales – From Geometric Part Details to Construction Elements

Project C 03

Integration of Passive and Active Functions in Additively Manufactured Construction Elements

Project C 04

Integrating Digital Design and Additive Manufacturing through BIM-Based Decision Support and Digital Twin Methods

Project C 05

Jointing Principles for Combination of Concrete Elements Produced by Different Additive Manufacturing Processes

Project C 06

Integration of Additive Manufacturing in the Construction Process

Project C 09

Environmental Life Cycle Assessment – Determination of Ecological Sustainability Potentials by AMC

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