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3D printing of glass 

Topology Optimization for 3D printed glass structures in an architectural scale

​Following up on the research of TU Delft on the use of Topology Optimization for engineering massive cast glass structures, the TU Delft team, in collaboration with Evenline and MIT, are investigating the development of a Topology Optimization (TO) algorithm for large-scale 3D-printed glass structures in architecture.
 

The potential of 3D printed glass in architecture

Additive manufacturing (AM) of glass is still at an early stage of development; yet it displays great potential for revolutionizing glass architecture through the fabrication of glass structures of unpreceded design freedom. Simultaneously, AM contributes to minimizing waste in construction by creating mould-free structures of reduced volume and embodied energy and through the potential use of wate glass as the raw material. Prototype work by MIT and Evenline has successfully showcased the potential of using glass 3D printing for manufacturing freeform glass components in architectural scale.

Development of a Topology Optimization code for 3D printed glass structures

Glass 3D printing is subject to several fabrication limitations, with the major ones being a restriction to the achievable overhang, the need of a continuous printing path, and a path offset to reflect the nozzle size. It is therefore crucial to implement these limitations already during design stage to be able to generate feasible 3D-printed glass designs for the built environment. Although algorithms that consider such fabrication limitations exist in other 3D printed materials, there is not yet a Topology Optimization (TO) algorithm formulated specifically for glass 3D-printing as a fabrication process. Relevant TO algorithms for glass have been already developed by TU Delft for the design of massive cast glass structures; however, these integrate fabrication limitations linked to casting, which are neither fully encountered, nor fully applicable to glass printing. By building into our existing knowledge on the formulation of TO algorithms for cast glass structures and in collaboration with MIT and Evenline, we introduce the first TO algorithm specifically developed for 3D printed glass, integrating relevant fabrication limitations, such as an overhang restriction, the necessity for a continuous printing path and for path offsetting, while considering the substantial difference between the tensile and compressive strength of glass. The feasibility of the algorithm is validated through the first-ever 3D-printed, topology optimized glass component in the form of a stepping stone. Future research will focus on the further development of the Topology Optimization algorithm and on developing assembly systems for 3D printed glass structures made of numerous components.

Credits

R&D:  TU Delft (Pim Brueren, Faidra Oikonomopoulou, Charalampos Andriotis, Telesilla Bristogianni) in collaboration with

           Evenline (Ethan Townsend, Michael Stern) and

           MIT (Daniel Massimino, Kaitlyn Becker)

Prototype printing: Evenline

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