Fabrication-aware structural optimisation of lattice additive-manufactured with robot-arm

Abstract

Architectural structures achieving high strength and stiffness with intelligent, but intricate geometry may now be materialisable through additive manufacturing (AM). However, conventional layer-based AM also produces parts with inconsistent structural strength - thereby limiting AM's end-use applications. Expanding on robotics-enabled AM techniques addressing this limitation, a novel design-fabrication framework for producing structurally optimised lattices is presented here. Lattices are geometrically morphed to maximise their structural stiffness-to-weight ratio while respecting fabrication constraints imposed by the robotic printing process, and converted into tool-paths for PLA extrusion with a custom-built end effector mounted on an industrial robot arm. The printing process leverages thermal imaging for calibration, and develops a novel joint detail to increase the reliability and load-transfer capabilities of the print. Together, these techniques and methods - validated through comparative structural load testing - show promise for architecture-scale AM that combines structurally driven geometry with complexity-agnostic materialisation in new and exciting ways.