Authors
M. Becker, A. Fromm, P. Mecke, F. Keller
Abstract
The paper describes how established manufacturing methods and certified materials in metal casting are used in conjunction with 3D-printed moulds for creating geometrically complex structural aluminium connectors. To show the potential of this process we propose a novel connector that differs from bespoke tube connectors and traditional spider fittings. We showcase a connector for joining sheet material to form larger double-layered structural assemblies such as decks and shells without the need of any substructure.
The work lays out the digital process chain including design, engineering, and fabrication. This includes topology optimization of connectors towards structure, material use, and casting limitations. It describes the production of individually shaped connectors, which are produced indirectly using a large format binder-jet 3D-sand-printer for casting metal cores. It results in bespoke cast metal connectors with approved material properties. The work is situated between 3D-metal printing and 3D-printing sand moulds for bespoke metal casting.
A possible novel design application of such a plate connector is demonstrated in a shingled double-layered structure. It would allow for a loose-fit overlapping panel detail and thus eliminate elaborate flank machining. Such varying overlap between panels with relatively large tolerances also opens the possibility for constructing nonstandard forms out of standard panels. It also allows to design with reused plates or production-waste material by employing combinatorial methods.
