Rationalization Algorithm for a Topologically-Optimized Multi-Branch Node for Manufacturing by Metal Printing

In the last few years, additive manufacturing (AM) technologies has enabled engineers to design and develop several products with complex geometries, which could not be easily built by conventional manufacturing methods. Furthermore, AM application has been extended from solely making prototypes to develop end-use components in different industry sectors such as civic, aerospace, medical and etc. One of the earliest additive manufacturing methods known as metal printing allows us to produce more performative components in industries, however due to some limitations, this method claims different strategies of design for additive manufacturing (DFAM). In this research, a construction component, namely multi branch node, which is used in space frame (SF), is chosen as a platform in order to implement the design strategy on its surface using a rationalization algorithm. At first, a multi branch node is simply sketched using the dimensional information of SF’s converging bars into a specific node. Then, a topology optimization analysis is performed by reducing the aforementioned volume from the specific section of the node to achieve the minimum strain energy. Finally, a rationalization algorithm namely, mesh-matching technique is implemented on a topologically-optimized node in order to make it more compatible with the metal printing and additionally provide safety and structural advantages compared to the original node