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Employing additive manufacturing to create reusable TPU formworks for casting topologically optimized facade panels
Journal of Building Engineering ( IF 6.4 ) Pub Date : 2023-06-02 , DOI: 10.1016/j.jobe.2023.106946
Niloufar Emami

Concrete is a building material with excellent structural qualities that can be molded into any shape. However, it is also responsible for approximately 8% of the world's total greenhouse gas emissions. There is a need to reduce material consumption during the design and construction of concrete structures. This research proposes a new manufacturing workflow for the design and fabrication of precast façade panels. Structural topology optimization (TO) is used to design perforated façade panels with optimized material distribution according to the panel's connection to a sub-structure. Structural simulations are conducted to validate the stiffness and strength of the TO panels. Finally, flexible Thermoplastic Polyurethane (TPU) molds are additively manufactured and repeatedly cast. The study results show that TO decreases the panels' volumes within a predefined WWR by anywhere from 23% to 30% of the total volume, while maintaining satisfactory structural performance. Additionally, the study demonstrates the potential of additively manufactured TPU molds for the repeatable casting of concrete while accommodating undercuts in the complex cast geometries. This study is novel as TO has not previously been used for designing façade panels. Furthermore, the use of 3D printed flexible molds made of TPU for repeatable casting of geometries is still in its early stages, with only one publication reporting the investigations at the time of writing this article. This workflow is innovative as a whole as it addresses material saving in the design phase through TO, as well as the creation of reusable 3D printed formworks in the fabrication phase.



中文翻译:

采用增材制造创建可重复使用的 TPU 模板,用于铸造拓扑优化的外墙板

混凝土是一种建筑材料,具有优良的结构质量,可以塑造成任何形状。然而,它也占世界温室气体排放总量的大约 8%。在混凝土结构的设计和施工过程中需要减少材料消耗。本研究为预制外墙板的设计和制造提出了新的制造流程。结构拓扑优化 (TO) 用于设计穿孔立面面板,根据面板与子结构的连接优化材料分布。进行结构模拟以验证 TO 面板的刚度和强度。最后,柔性热塑性塑料聚氨酯 (TPU) 模具采用增材制造并反复铸造。研究结果表明,TO 在预定义的 WWR 范围内将面板体积减少了总体积的 23% 至 30%,同时保持了令人满意的结构性能。此外,该研究还展示了增材制造的 TPU 模具在可重复浇注混凝土同时适应复杂浇注几何形状中的底切的潜力。这项研究是新颖的,因为 TO 以前没有用于设计外墙面板。此外,使用由 TPU 制成的 3D 打印柔性模具进行几何形状的可重复铸造仍处于早期阶段,在撰写本文时只有一份出版物报告了调查结果。制造阶段的模板。

更新日期:2023-06-02
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