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Architecture, Structures and Construction (2022) 2:565–574

https://doi.org/10.1007/s44150-022-00050-z

ORIGINAL PAPER

3d printing of column structures for architectural applications


B. Waldschmitt1 · C. Borg Costanzi2 · U. Knaack2 · J. Lange1

Received: 31 December 2021 / Accepted: 23 April 2022 / Published online: 23 May 2022
© The Author(s) 2022

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.

Keywords Wire Arc Additive Manufacturing · AM · parametric robot programming · Design to production workflow

Introduction to WAAM in which a welding/filler wire serves as the printing


material. To achieve the desired target geometry and
In addition to the classic manufacturing processes of properties, various welding wires - both the usual welding
material removal and forming, additive manufacturing wires made of carbon steel, e.g. G3Si1 [1] as well as
(AM) is another process that has emerged in the various stainless steels [2] – are used. The liquid molten
manufacturing industry. It can be used to serve complex pool, which is produced by the electric arc solidifies in
geometric requirements and allows for integrating lines or spots and forms three-dimensional structures. The
functionality in areas that cannot be provided by traditional selection of the wire electrode significantly determines the
manufacturing processes or only at extremely high cost. material characteristics of the manufactured structure. The
Several of these building materials e.g. concrete and their shielding gas serves on the one hand to protect the seam
application cases are under research by the construction from atmospheric influences and impurities, and on the
industry as well and therefore seem to be a prospective other hand it stabilizes the heat input of the welding process
tool of this branch. For the steel construction industry the and influences the molten pool [3]. Compared to other
research into Wire Arc Additive Manufacturing (WAAM) metallic additive manufacturing processes, the WAAM is
has raised attention. WAAM is an additive manufacturing characterized by a 30 to 40-fold higher application rate [4].
process based on gas shielded metal arc welding (GMAW), At the same time, investment costs for system technology
and supplies are significantly lower [5]. Six-axis robotic
systems, shown in Fig. 1, for guiding the welding torch
* B. Waldschmitt offer greater flexibility in the manufacturing of components
waldschmitt@stahlbau.tu-darmstadt.de
and are used to ensure production in large installation
1
Technical University of Darmstadt, Institute for Steel spaces. With increasing size, accuracy decreases as the
Construction and Materials Mechanics, Darmstadt, Germany distance to the machine origin extends [6]. These aspects
2
Technical University of Darmstadt, Institute for Structural make the process attractive for the manufacture of large
Mechanics and Design, Darmstadt, Germany architectural components like free form columns.

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Vol.:(0123456789)
566 Architecture, Structures and Construction (2022) 2:565–574

Fig. 1  Six-axis robotic system


for Wire Arc Additive Manufac-
turing at the laboratory of the
IFSW and ISMD at TU Darm-
stadt, manufacturing two scaled
column structures parallelly

Column Structures Investigated 3d printed column structures

Introduction The research presented in this paper lies within the context
of combining digital design tools and WAAM to manufac-
The diversified availability of digital design tools and fab- ture performative and expressive column structures, which
rication techniques has allowed architects to realize more are cost-intensive or impossible to produce using conven-
expressive and performative structures. This is particularly tional manufacturing processes. The column structures of
apparent in the context of additive manufacturing, where our choice are shown as scale models in Figs. 2a and f. The
standardized structural systems, including floor slabs [7], transfer to large column structures spanning several meters
walls [8] and beams [9] are reimagined as geometrically- and adapted wall thicknesses is equally possible, but limited
complex and structurally-efficient members. The same may by the radius of action of the robot. In these cases, the entire
also be said for column-type structures; the researchers at structure must be manufactured in segments, at the end of
Bologna University, together with MX3D, illustrated the which the individual components are welded together either
potentials of combining digital design tools with additive in the factory or on the construction site.
manufacturing by producing a large-scale lattice-type col- While model (a) consists of an additively manufactured
umn structure [2]. Similarly, researchers at ETH Zurich column with an octagonal cross-section, which gradually
also made use of the creative freedoms that AM had to twists as height increases, showcasing some of the possibili-
offer and incorporated these into the design of column ties for expressive architectural shapes (Figs. 2b and c), the
structures; The Smart Dynamic Casting (SDC) used an column (f) is manufactured as a structure with an ellipsoid
adaptable slip-formwork to gradually build up reinforced cross-section (d) of varying width. It forms the basis for the
concrete columns with varying cross-section [10]. Build- manufacturing of a column shape shown in Fig. 2e, whose
ing on the use of generative design tools to inform archi- cross-sectional dimensions are maximum in the center col-
tectural systems, the Subdivided Columns by Hansmeyer umn height and tapered in the area of the supports. The
[11] are a result of generating ornamental textures through designed column shapes can correspond to varying force
a set of pre-defined design rules. As Hansmeyer describes, distributions and still be architecturally appealing. In this
the architect is placed in the position of developing a set case, the structure is given a smaller cross-sectional area at
of design rules, particularly, the subdivision of an initial the base and top, where bending moments are expected to
mesh geometry, which may be continuously run to create be less due to a hinged bearing, and a larger cross-sectional
endless permutations of ornamental column structures; area in the center.
effectively rendering an architect as an orchestrator rather Although the structures are relatively simple in terms
than designer. of geometry (Figs. 2a and f), they are intended to serve as

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Architecture, Structures and Construction (2022) 2:565–574 567

Fig. 2  Investigated column structures with a twisting octagon cross section (a-c) and an changing ellipsoid cross section (d-f)

the first iteration into more geometrically-complex columns to adjust robotic motion paths, layer-heights and welding
defined by material deposition limitations such as maximum parameters is critical to ensure a stable printing process.
overhangs, minimum cross-sectional areas and wall thick- In response, this research establishes a workflow from
nesses. This approach of manufacturing could be combined design to production (Fig. 3). The digital model, generated
with other design factors such as shape optimization in order with the design tool Rhinoceros 3d, contains information on
to maximize load carrying capacity. Column (f), which is process and input parameters, welding layer geometries and
not intended for load bearing capacity tests, forms the basis material properties. The weld paths are generated by means
of this paper, where mainly the feasibility for additively of parametric robot programming (PRP), a coordinate deter-
manufactured columns, with highly variable cross sections mination based on mathematical functions (see chapter Para-
- stronger than for (f) - will be investigated. Moving forward metric Robot Programming). A feedback of information from
we will also focus on the "design to production" workflow the column in production with the digital model by the robot
for additive manufacturing of the structure. controller enables adaptive updating of the weld paths accord-
ing to the required production.
During manufacturing, data like welding, cooling, measuring
Design to Production Workflow and movement times, as well as the measured layer heights of
the manufactured structure are recorded for each layer. The final
One of the common misconceptions in additive manu- evaluation of the recorded data, supplemented by 3D scanning for
facturing is that it is a “plug-and-play” process, in which a target/actual comparison, is used to generate welding and milling
a 3D model is divided into layers (slicing), which are trajectories for a surface finish, which is not part of this article, as
then converted into motion instructions, or g-code which well as to determine, for example, optimized movement sequences
is uploaded to a printer. With such a setup, the flow of or cooling and measuring processes. All stored information results
information between the digital model and the printed in a rudimentary Digital Twin within the design tool. This was
geometry stops there; and the ability to adaptively update essential in ensuing proper process control as it allowed for a par-
the position of a 3D printer in response to the printed tially real-time feedback of information between the initial 3D
geometry is lost. In reality, there are often differences, geometry and data generated during the printing process.
especially in WAAM, some of which may be quite sig-
nificant, between a design geometry and what is actually Process and input parameters
printed. These variances may include, but are not lim-
ited to, discrepancies in layer heights or distortion of the A layer deposition under a stable welding process depends
printed structure during printing. Therefore, the ability significantly on the selected welding and input parameters,

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568 Architecture, Structures and Construction (2022) 2:565–574

Fig. 3  Design to production workflow

which influence the geometric dimensions of a weld layer


and the subsequent material properties [12]. The material Table 1  Process and input parameters for CMT Cycle Step
deposition is decisively controlled by the defined travel Process and input parameter Variable Unit
speed (TS), the wire feed speed (WFS) and the CMT process
regulation [13]. Fronius offers the "CMT Cycle Step", a Number of CMT-Cycles 15 - 25
welding process in which the ratio of material application Pause time 80 – 120 ms
(CMT cycles) to the predefined pause interval for the Wire-Feed Speed (set) 6.0 m/min
solidification of the melt can be selectively controlled. This Travel-Speed 0.6 m/min
targeted control is essential for the additive manufacturing Shield gas Ferroline C6X1 (93 % Argon,
6 % ­CO2, 1 % ­O2)
of free-formed column structures with overlaying layer
Gas-flow rate 15 l/min
deposition, for which dripping of the molten material (Fig. 6)
Wire electrode Weko 2 G3Si1 (ER70 S-6)
must be prevented. Table 1 lists the welding parameters for a Ø 1.2 mm
Fronius CMT Advanced 4000 R welding source with a CMT Welding torch orientation 90° to the horizontal
Cycle Step characteristic and relevant process parameters. Cooling time (set) 25 - 45 s
To prevent the weld metal from dripping a cooling,
explained in detail in chapter Process Sequence Parameters,
is set after each welding so the structures can cool down.
material characteristics and standard deviation for each ten-
Material characteristics sile specimen sample line – consisting of three samples each
- according to DIN 50125 - E [15] are given. They were
To determine the load-bearing capacity of an additively recorded in tensile tests on a universal testing machine of the
manufactured structure, the material properties were first Institute for Steel Construction and Materials Mechanics of
determined. Table 2 lists the minimal material properties the Technical University of Darmstadt with a maximum ten-
of the wire electrodes Weko 2 G3Si1 and Weko 2 G4Si1 sile or compressive force of 100 kN. The specimens samples
which serve as a reference [14]. Then the measured average 1Seam-milled-45 and 1Seam-milled-90 were milled out of

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Architecture, Structures and Construction (2022) 2:565–574 569

Table 2  Material characteristics Yield strength ­Re Ultimate strength ­fu Elongiation at
(Average and standard in N/mm2 in N/mm2 fracture in %
deviation)
G3Si1 and G4Si1 (WDI) 420 520 25
1Seam-milled-45 471 ± 10 567 ± 10 25 ± 1
1Seam-milled-90 423 ± 3 534 ± 4 30 ± 3
2Seams-milled-0 419 ± 10 521 ± 10 27 ± 3
2Seams-as built-0 428 ± 6 538 ± 3 25 ± 1

cantilevered wall structures (shown in Fig. 4d). They consist Parametric Robot Programming
of one welding seam per layer with an inclination of 45° and
90° to a vertical material deposition. More detailed infor- Central to the ability to update welding paths according to
mation can be found in [16]. The specimens of 2Seams-as recorded information is the use of Parametric Robot Program-
built-0 (b) and 2Seams-milled-0 (c) were printed vertically ming (PRP). This process, which has already been illustrated
with two welding seams in each layer (a), providing milled in [17], differs from conventional robot programming in that
and as built surfaces. coordinates are generated by means of mathematical functions
In addition to the yield strength ­Re and the ultimate which are defined by information recorded during the printing
strength ­fu, the elongations at fracture were determined process. Due to the fact that in conventional slicing (Fig. 5a),
according to DIN EN ISO 6892-1 eq. 6. However, the focus every single coordinate has to be precalculated and sent as a
of these investigations is on the ultimate strength. line of code, the data files generated by PRP (Fig. 5b) are, in
The results show, that the minimum yield strength and most cases, far smaller than conventional ones. In PRP, a series
the minimum ultimate strength are almost equal or slightly of loops are used to define each layer and equations (right)
above (except 1Seam-milled-45) the wire manufacturer's illustrate how an ellipsoid with varying cross-section can be
specifications within the range of the standard deviation. defined by two loops using Cosine and Sine angles.
The same applies to the measured elongation at fracture. The manufactured columns are characterized by a layer
The consistent results allow using the material properties of deposition with continuously changing transverse offset
the wire electrode as parameters for the rudimentary digital which influences the layer height. Fig. 6a schematically
twin while they should be supplemented by means of further illustrates the material deposition in vertical orientation and
tensile tests. for different overhang angles αt shown in Fig. 6b to d. Up to

Fig. 4  Manufacturing of tensile


specimens; wall structures
printed vertically by 2 seams
(a); exemplary tensile speci-
mens with as built surface (b)
and milled surface (c); cantile-
vered wall structures for each
tensile sample line (d)

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570 Architecture, Structures and Construction (2022) 2:565–574

Fig. 5  Principal of the conventional motion controlled slicing (a) and parametric robot programming (b)

a horizontal offset of about 10 % of the weld thickness t, a piece changes. In case of significant deviations, this has an
stable process results with angles αt and in layer heights h influence on the layer width and height to be applied, which
depending on the selected offset (Fig. 6e) would further cause an unplanned manufacturing of the
Above α0.25t, the molten material starts to drip off under column geometry and could lead to an interruption of the
neutral torch position [16, 18], so that an unforeseen loss welding process. The PRP prevents this error development
of material and height occurs. In addition, the contact tip during the manufacturing process by dynamically adjusted
to work distance (CTWD) which describes the distance weld paths through permanent monitoring of the geometric
between the contact tip of the welding gun and the work height development of the column structure.

Fig. 6  Printing Overhangs with 90° to the horizontal orientated welding gun

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Architecture, Structures and Construction (2022) 2:565–574 571

Process Sequence Parameters investigations to enable a precision of 0.2 mm accuracy.


These included the CTWD, the motion and acceleration
WAAM offers various possibilities of building structures. profile of the robot, the orientation of the welding torch to
The manufacture of each individual layer is determined by the target surface and the distance at the start of the tactile
the process sequence parameters. These are shown in Fig.7. measurement. Fig. 8c (right) shows the results of 18 points
First, the x and y coordinates of the 150 weld path coor- from every ­10th measured layer. These are used to determine
dinates are calculated as a function of the height that has a layer height by section. Erroneous measurements outside
already been manufactured. of a tolerance range of ±1.5 mm to the expected layer height
It includes a slight change of the starting welding point (caused by welding slags for example) are firstly remeasured
of each layer (shown in Fig. 8c (left)) because at a constant and then not taken into account in case they still consist.
speed, welds are higher at the starting point and lower at the
end-point than in the rest area [19]. In addition the welding
seam thickness at the start point is increased. To prevent a Evaluation
punctual error propagation of the layer height, the starting
point of each layer was changed by an additional rotation For the 52.2 cm high scaled column model, shown in Fig. 8a,
angle. The layer than can be welded with the welding and 400 welding layers were applied. This corresponds to an
input parameters given above while welding data and time average layer height of 1.304 mm. The ellipse had maximum
consumption is saved to the twin. major and minor radii of 150 mm and 100 mm respectively
To ensure an interpass layer temperature of less than and a minimum cross sectional dimension of 32 mm. Fig. 8b
150 °C and a reduction of the cooling time, the columns shows the evaluation of the manufacturing process and the
are cooled for at least 25 s with an automated compressed result of the target/actual comparison.
air cooling system with additional water mixture. The It shows one side of the target/actual comparison of the
control was carried out with a pyrometer at the upper last digital model and the scanned solid model determined by
applied welding layers. A converted minimum quantity means of the FARO Freestyle 2 handheld scanner (left) and
lubrication system with water was used for the purpose of the rendered surface (right). The deviations are homogene-
cooling. The water evaporates on the surface of the col- ous, and range between 0.0 to 0.3 mm from the lower to the
umn, extracting the heat from the body faster than it would upper part, with a maximum of 0.8 mm at the upper edge
for pure compressed air. No negative influences on the of the column.
metallurgical properties and microstructures were detected At this point, the scan result shows a lower accuracy. This
for this cooling method [20]. is highlighted by the dot-like dark grey areas of the rendered
The touch sensing method – a tactile measuring method scan of the right half of the column, which are not shown
– is used to measure the current z-height of the structure. in Fig. 8a.
For this process the filler wire is automatically cut by a wire Fig. 8c (left) shows the progression of the coordinate
cutting station to a defined length and a small voltage is points and their changing horizontal distance, ∆d, for each
applied. While slowly moving the wire vertically onto the layer. In the section of the tapered cross-section between lay-
workpiece the respective coordinates of the wire touching ers 200 to 300, the distance decreases below the limit value
the surface are recorded by the robot. These coordinates can to be processed by the robot controller. In this area, only
now be used to calculate the corresponding layer height. every fifth weld path coordinate has to be approached due
This is executed automatically by the program code so the to the weld path density. The geometry of the column is not
CTWD stays on a constant value. unexpectedly affected by this. Illustrated in Fig. 8c (right)
Similar to the welding parameters, characteristics influ- the evaluation of the tactile height measuring for every ­10th
encing the measurement were examined in preliminary layer over one half of the column is given. The vertically sig-
nificantly deviating measurement shown in the enlargement

Fig. 7  Schematic chart of the process sequence of each layer

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572 Architecture, Structures and Construction (2022) 2:565–574

Fig. 8  Evaluation of the column


structure; final printed object
(a); target/actual comparison
(b); illustration of the height
measurements by touch-sensing
method (c) and graphical evalu-
ation of the time consumption
(d)

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Architecture, Structures and Construction (2022) 2:565–574 573

– the measured height is in the existing structure – is errone- Funding Open Access funding enabled and organized by Projekt
ous and was not taken into account in the averaged height DEAL. This research was funded by the Bundesministerium für
Wirtschaft und Energie (Grant Number: 16KN076133).
determination consisting of 18 recorded values. The small
number of faulty deflections illustrates the reliability of the
Declarations
information generated by the touch-sensing method for the
rudimentary digital twin. Conflict of interest On behalf of all authors, the corresponding author
Fig. 8d shows the time spent for the manufacturing of states that there is no conflict of interest.
the column divided into welding time (continuous line),
cooling time (dotted line) and measuring time (crosses) Open Access This article is licensed under a Creative Commons Attri-
for the tactile detection of the layer heights. The 10 bution 4.0 International License, which permits use, sharing, adapta-
tion, distribution and reproduction in any medium or format, as long
fluctuations of the red curve, especially up to layer 100, as you give appropriate credit to the original author(s) and the source,
indicate interruptions in the welding process, e.g. due to provide a link to the Creative Commons licence, and indicate if changes
wire stuck, which led to an interruption of the material were made. The images or other third party material in this article are
deposition. The applied mass of 5.12 kg was deposited included in the article's Creative Commons licence, unless indicated
otherwise in a credit line to the material. If material is not included in
within 3.35 hours of pure welding time, which corresponds the article's Creative Commons licence and your intended use is not
to a deposition rate of 1.52 kg/h. The red curve shows a permitted by statutory regulation or exceeds the permitted use, you will
variation in the course of the cooling time. The different need to obtain permission directly from the copyright holder. To view a
lengths of the tactile measurement processes are the result copy of this licence, visit http://​creat​iveco​mmons.​org/​licen​ses/​by/4.​0/.
of faulty measurements, which meant that measurements
had to be repeated.
All evaluated data are stored in the rudimentary digital References
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