Node-Based Shape Optimization and Mechanical Test Validation of Complex Metal Components and Support Structures, Manufactured by Laser Powder Bed Fusion

Vertex morphing parametrization in combination with node-based shape optimization has proven to be invaluable in improving the initial engineering designs as it offers the largest possible design space. In this contribution, these optimization procedures were applied to additively manufactured components with the aim to improve their mechanical properties. The components present the nodes of a tensegrity-tower, which is designed and realized by the Technical University of Munich and will be built at the Deutsches Museum in Munich in 2021. The nodes are highly complex connections between the compression rods and cables of the tower. They are made of aluminum and manufactured using laser powder bed fusion of metals (PBF-LB/M/AlSi10Mg). After the optimization, the nodes were printed and tested mechanically to validate and verify the numerical optimization results. Finally, an attempt to optimize the support structure required for the additive manufacturing process is presented.