Generative Structural Design: A Cross-Platform Design and Optimization Workflow for Additive Manufacturing

This paper explores a generative design, simulation, and optimization workflow for full-scale 3D printed building components using an array of different mixtures. Large-scale additive manufacturing in conjunction with algorithmic CAD design tools enables a vast amount of control when creating geometry. This can also be advantageous regarding the increasing demands to use more resourceful and sustainable construction methods and materials. The presented methodology aims to highlight these new technological advancements and offers a multimodal and integrative design solution with the potential for an immediate application in the AEC-Industry. The presented work will investigate a case study based on a structurally optimized waffle or two-way joist slab. The goal is to create permanent formwork that serves as molds during the pouring and fabrication process on-site and validates the structural integrity of those 3d concrete printed molds. For this, a hybrid validation strategy, using a digital and cross-platform simulation environment that is audited with physical prototyping is investigated. Various geometric attributes are parameterized and can be imported to a finite element method (FEM) software via a custom workflow. Here the structural behaviors and failure patterns of the molds during the pouring process are examined and incrementally optimized to satisfy minimum structural performance requirements to ultimately withstand the pressure of the cast-in-situ concrete. Subsequently, alternative and hybrid mixtures and materials, e.g., foam concrete and eco-friendly composites are numerically evaluated and compared. The results are fed back to the parametric design model to further optimize the generative workflow.