3D‐Printing with Steel ‐ Additive Manufacturing Connections and Structures

Abstract

Automated production is finding its way into fabrication of structural steel. One robot holds attachments (stiffeners, head plates, etc.) to a steel beam or column and another robot produces weld seams. However, welding robots can also be used for additive manufacturing (Wire + Arc Additive Manufacturing, WAAM). The wire electrode serves as printing material. The Institute for Steel Construction and Materials Mechanics in Darmstadt is investigating how typical connecting elements of steel construction can be printed directly on steel beams using Additive Manufacturing with arc welding and robots. Furthermore structural elements like nodal points are printed and even complete structures like columns and a little bridge have been manufactured additively already. The main focus is on determining suitable welding and process parameters. In addition, topology optimization is used to find good structures using a low amount of material. This is possible due to the free design prospects of 3D‐printing. This opens for novel design and production strategies.