Towards the Integration of Additive Manufacturing for Freeform Steel and Glass Façade Construction

The thesis, titled ‘Towards the Integration of Additive Manufacturing for Freeform Steel and Glass Façade Construction,’ explores the transformative role of additive manufacturing (AM) in enhancing the design and construction of Freeform Steel and Glass Façades (FFSGF). These façades involve intricate components, necessitating collaborative efforts among designers, engineers, and fabricators to achieve complex façade geometries with good performance while ensuring efficiency in design, material usage, fabrication, and cost. Recent advancements in AM technology have made it a potentially viable and increasingly accessible fabrication strategy, particularly for mass-customized components such as those used in freeform construction. The research aims to answer the central question of how AM can effectively contribute to developing node solutions supporting Freeform Steel & Glass Façade (FFSGF) construction.The study systematically examines opportunities for improvement in existing solutions. Chapters 2 and 3 provide a critical overview of FFSGF construction typologies and explore the current landscape of AM in façade applications. Chapters 4 and 5 delve into the design and development of crucial components—structural nodes and gasket nodes—utilizing different AM technologies. Prototypes are manufactured and evaluated in comparison to existing solutions. Chapter 6 provides a case study of integrating AM product development into a larger construction project, emphasizing interdisciplinary collaboration. The thesis underlines the advantages of the systemization of AM node design throughout the design and fabrication of AM nodes. This research contributes to the evolving knowledge at the intersection of design, engineering, construction, and AM, aiming to provide a valuable resource for building industry professionals navigating the complexities of incorporating AM into the fabrication of freeform steel and glass façades.