3d printing of column structures for architectural applications

Abstract

Wire Arc Additive Manufacturing (WAAM) is a welding process used to build up three-dimensional structures in steel. Like other Additive Manufacturing technologies, it allows for geometrically-complex structures to be fabricated which are otherwise unfeasible to manufacture using traditional methods. This research paper presents an integrated design approach to the use of WAAM in the context of large-scaled applications, focusing on column variants of gradually-increasing geometric complexity as basis for architectural constructions. It combines material behavior and process para-meter research together with a rudimentary digital twin model, with the aim of providing a digital tool to design architectural structures for WAAM. To achieve the desired geometries, necessary welding parameters are stored and applied to the digital twin model. This is complimented by multiple process-control checks, which are implemented during the printing process to ensure that an object is generated as planned. Finally, the structures are manufactured and are subjected to a critical evaluation in order to identify the possible future potential. The challenge of combining geometric complexity with manufacturing for large scale represents a next step in the integration of WAAM in steel constructions for architectural applications.