Free-form façade with 3D printed steel nodes

research and development, special structures Services

Architect

Additive manufacturing of free-form steel and glass structures

Project

As part of a research collaboration with Jansen AG and TU Delft, the potential of 3D printing technologies for manufacturing components for freeform steel-glass structures was explored, and a mock-up was realized. Additive manufacturing (AM), widely known as 3D printing, is a forward-looking technology that enables an unprecedented degree of design freedom for steel system façades. The 3D-printed steel nodes are highly customizable and can be designed with multiple arms and variable angles—ranging from sharp to obtuse within a single node. The developed VISS³ façade is a self-supporting structure: loads are transferred directly via the profiles and connection nodes, eliminating the need for an additional substructure.

Comparison of additive manufacturing processes and development of structural nodes for complex geometries

Structural node design

Various additive manufacturing (AM) processes for producing structural nodes in freeform steel-glass constructions were analyzed and compared. A distinct node design was developed for each selected AM method, ensuring compatibility with the Jansen VISS façade system. However, the node chosen for the final prototype does not allow a definitive assessment of which printing process is best suited for this type of application. The optimal printing method for a specific construction project depends on a variety of design parameters, including size, structural requirements, desired geometry, and surface quality.

The realization of the freeform AM prototype façade is based on a digital parametric process chain that allows for high flexibility throughout the design investigation.

Parametric Workflow

The realization of the AM prototype façade is based on a digital parametric process chain, spanning from geometry development and structural analysis in the SOFISTIK software to the generation of CAM models. The parametric workflow is carried out in five phases. These phases are subdivided in the definition to allow local management in case the node design changes in future projects. The phase of manufacturing complex parts is further divided by features to avoid long computation times when modeling highly precise features. This workflow provides significant flexibility during the design investigation and when progressing to other applications.