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Background

3D printed or additive manufacturing processes have gained increasing interest within the discussion of digital fabrication and architecture. While additive manufacturing of metals has reached, production scaled efficiency and cost feasibility within medical, aerospace and aviation manufacturing industries, it does not have significant presence within the building or construction industries. This research anticipates the inevitable intersection with large scaled building construction. The key topics for exploration are geometric complexity, mass customization, localized structural optimization, and integrated multi-functionality. The implementation of each of these is challenged at the scope typical of stadium architectures and high-rise towers. The research seeks to address each of these topics at both the scale of one-off prototypes as well as full-scope work flow implementation. Software limitations are being examined, and where necessary new applications are being developed to leverage the benefits unique to this manufacturing process.

Creating Inspiring Details
with 3D Printed Metal.

A full range of benefits can be realized through 3D printed or additively manufactured metal building components. The benefits include the higher degree of design freedom and access to aesthetic complexity, the ability to produce non-standardized parts which can therefore be locally optimized for several performance criteria such as structural efficiency or geometric specificity, as well as a more streamlined design-to-fabrication work flow which minimized coordination and documentation.

A New Era of Fabrication

3D printed metals enable the production of one-off parts with a high degree of complexity. Since the component cost for 3D printed parts are not linked with standardization or repeatability, parts can be geometrically customized and engineered specifically to their locations within the building’s structure. Typically parts are engineered and standardized to a worst case loading situation and limited to a geometry which offers the highest degree of repeatability. This leads to a high degree of over sized or over engineered pieces within the structure and can contribute to additional weight and excess material consumption.

The ability to locally optimize each component therefore leads to a significant reduction in material consumption and weight while satisfying loading requirements and safety factors specific to each component. These features also enable a higher degree of aesthetic or formal freedom to the building.