Exploring the Potential of Topology Optimization and Additive Manufacturing in Architecture

• Infrastructure as a Service (IaaS) - Cloud Computing

• Buildings
• Education

• Logistics & Transportation
• Product Research & Development

• Additive Manufacturing
• Rapid Prototyping

The case study revolves around the exploration of the potential benefits of combining topology optimization and additive manufacturing in architectural projects. While this combination is common in industries like automotive or aerospace, it is rarely used in architecture. The challenge was to investigate the potential of this symbiosis for architectural projects. Bayu Prayudhi, an architectural student of the University of Delft, took up this challenge and re-designed an existing architectural project, the outdoor canopy at Baku international airport in Azerbaijan, originally designed by ARUP. The goal was to include topology optimization upfront in the design process and adapt the design for 3D printing. The challenge also involved dealing with boundary conditions such as costs, lead times, and technological limits while striving to combine function, shape, and innovation.

The customer in this case study is Bayu Prayudhi, an architectural student at the University of Delft. He undertook the project to investigate the potential of the symbiosis of topology optimization and additive manufacturing for architectural projects. He chose an existing project, an outdoor canopy, designed by ARUP, located at Baku international airport in Azerbaijan for his study. Bayu was supported and supervised by his mentor, Dr. Michela Turrin and Prof. Dr. Ing. U. Knaack, from the department of Architectural Engineering and Technology at TU Delft and Shibo Ren, a Senior Structural Engineer, Buildings Amsterdam at ARUP. The Faculty of Architecture and the Built Environment of TU Delft, where Bayu is studying, has a leading role in architecture education and research in the broadest sense.

The solution involved the use of Altair's HyperWorks suite, especially OptiStruct for optimization tasks. The geometry was imported into HyperWorks and the occurring load cases were applied. Manufacturing constraints arising in additive manufacturing, such as supporting structures and printing direction, were then applied. The design space was defined and the optimization was performed on one node, using the numerical data of different occurring forces. The results were then extrapolated to estimate the impact an overall structural optimization might have. Since no 3D model of the original project was available, the design of the original structure had to be remodeled relying on approximation and assumptions. The total weight of all nodes was averaged. The new 3D printed design led to a potential weight reduction of approximately 32 percent. The use of OptiStruct helped to create a functional and visually captivating design ready for additive manufacturing.

• The combination of topology optimization and additive manufacturing led to a lower lead time, improved the overall design, and made it easier and faster to design simple connection parts. The simplified design of the connecting parts also led to a quicker and easier assembly process, which usually can be handled on site. This led to a reduced need to transport large pre-assembled structural parts. By using topology optimization and additive manufacturing, the overall construction time could be dramatically reduced, helping to also cut down general construction costs. The research also showed that designs created with topology optimization and additive manufacturing should not only be compared to traditionally designed and manufactured parts in terms of weight reduction or volume differences. A joint use of topology optimization and additive manufacturing could change the entire architectural creation process, from design to the actual construction, helping to save material, development and construction time and costs, while at the same time offering better and more esthetic results.

• The new canopy design led to a weight reduction of around 32 percent, bringing the total mass of the roof down from 34.9 tons to 23.7 tons.
• The overall area the canopy would cover increased from 417 to 423 square meters.
• The quad paneling design reduced the required amount of connection detail elements compared to the triangular design in terms of bulk volume and it helped to increase the efficiency of glazing manufacturing.