Towards the Integration of Additive Manufacturing for Freeform Steel and Glass Façade Construction

Abstract

The dissertation ‘Towards the integration of Additive Manufacturing for Freeform Steel and Glass Façade Construction’ explores the use of Additive Manufacturing (AM) as a means of improving the design and construction of Freeform Steel and Glass Façades (FFSGF). This type of construction involves the design, fabrication, and assembly of complex components, which requires close interdisciplinary collaboration to realize the architectural vision of the designer and achieve good façade performance while also striving for efficiency in design, material use, fabrication, construction, and cost.

Recent developments in additive manufacturing technology are making AM a more efficient, reliable, and accessible fabrication strategy for a range of different industries, scales, and materials. As such, it is quickly becoming an increasingly tenable fabrication method for the construction industry, and in particular, for the fabrication of mass-customized components such as those common in freeform construction. Therefore, seeing AM as an opportunity to improve on current fabrication strategies, this dissertation aims to answer the following question:

How can additive manufacturing be effectively utilized to develop node solutions that support freeform steel and glass façade construction?

The object of the research is to facilitate the integration of AM into the design and construction of future freeform steel and glass façades through the detailed exploration of different AM technologies for key components of freeform steel and glass façade assemblies. The research considers the impact of the use of AM over the entire design and construction process as well as on the roles and responsibilities of the different disciplines involved.

The first two chapters of this research (Chapters 2 and 3) comprise the background analysis to identify key opportunities and metrics by which existing solutions can potentially be improved upon. The research begins with identifying key opportunities for the use of AM by studying existing freeform steel and glass façade construction strategies. These are classified into general typologies for which the strengths and limitations are discussed. Following this, a literature review on the use of AM in façades is used to understand the extent to which AM technology has already been explored in this context.

Chapters 4 and 5 explore the design and development of two key components, namely a structural node and gasket node, respectively. Background research for these explorations comprise an overview of different possible AM methods, an overview of relevant design for additive manufacturing guidelines, and an assessment of the mechanical properties of the additively manufactured materials. Following this, physical prototypes are designed and printed using different AM technologies. For the structural node, three different nodes are designed per the design guidelines of selected metal AM methods. The three node prototypes are manufactured, and compared in terms of their fabrication efficiency and material efficiency. For the gasket node, a preliminary benchmark node design is printed using four different elastomeric AM methods and materials. A final node gasket is then designed, manufactured, and qualitatively compared to existing gasket solutions.

Chapter 6 discusses the integration of the product development undertaken in the previous two chapters in the larger context of a construction project. It is a case study outlining the way in which the design, development, and fabrication of AM products was conducted over the course of an interdisciplinary collaboration between a designer, an engineering team, and an execution team, for the realization of a full-scale freeform steel and glass façade. This chapter also outlines the digital strategy that was used to facilitate the interdisciplinary collaboration.

The dissertation concludes by discussing the main research question and proposing future research directions. The systemization of AM node design is recognized as a crucial aspect that can streamline the development process, facilitate standardization, and support the creation of libraries of interchangeable AM nodes. Limitations of the scope of research, such as the focus on specific AM methods and materials, are acknowledged. Areas for future research are identified including the further exploration of AM methods and materials, the development of AM components, the investigation of interdisciplinary design for AM, and the analysis of the role and impact of AM in sustainable construction practices. The study highlights the potential of AM in FFSGF construction, but it also emphasizes the importance of further exploration and optimization for AM to be effectively integrated as a viable and sustainable building practice.

AM technology has revolutionary potential when it comes to the fabrication of complex parts. As this technology continues to advance, it is quickly becoming a more accessible means of fabrication for the construction industry. That being said, its use, particularly for the realization of structural components, adds a layer of complexity to the already complex interdisciplinary undertaking that is the design and construction of freeform steel and glass façades. Unlocking the full potential of this revolutionary technology for these applications requires building a body of knowledge at the intersection of design, engineering, construction, and AM that building industry professionals can refer to in order to help facilitate the design and realization of additively manufactured parts and products. This dissertation aims to contribute to that growing body of knowledge.