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3d Printing of Column Structures For Architectural Applications
3d Printing of Column Structures For Architectural Applications
https://doi.org/10.1007/s44150-022-00050-z
ORIGINAL PAPER
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
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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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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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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
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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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– 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://creativecommons.org/licenses/by/4.0/.
of faulty measurements, which meant that measurements
had to be repeated.
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