3D Printing of Tubular Connectors for Space Frame Structures

In the construction industry, wire-based steel 3D printing (WBS-3DP) technology for structural parts has yet to be explored. As 3D printing becomes highly productive and cost-effective with the development of qualification standards, it opens a wide range of opportunities for the steel-based additive construction segment too. The major advantage of large-scale 3D printing techniques like wire-arc additive manufacturing (WAAM) is the ability to develop components that are more compatible through topology optimization and with the mechanical requirements of the structural standards. This research aims to discuss the application of WAAM in the fabrication of space frame structures for T-K-Y joints with structural integrity. In this study, a space frame structure was designed and developed with multi-branch tube connectors using WBS-3DP technology. These tube connectors are used to accommodate any number of steel tubes at arbitrary angles, such that the resulting T-K-Y joints are smooth and lightweight. The prototype space frame structure with a multi-branch tube connector is designed to demonstrate how the WAAM process can produce more efficient structures by eliminating challenges involved in tube joining and welding. Mainly there are three major challenges in the 3D printing of the tube connectors, such as transforming T-K-Y joints into a topology-optimized tube connector design; developing a tool path for the tube connector model, and printing the model by overcoming the issue of heat management. This paper also aims to bridge the gap between WBS-3DP and its application in the construction industry. It was concluded that WBS-3DP has the potential to revolutionize the construction industry by producing innovative parts such as tube connectors with ease of fabrication and improved digital construction techniques.