Continuum Optimization of 3D Printed Self-Supported Shell (2024-08)¶

Shell structures, commonly used due to their material efficiency, are susceptible to deformation and failure considering the curing time of materials like earthen or cement-based despite their strength. Additionally, they play a crucial role in construction, offering visually striking forms, design flexibility, and efficient load resistance. Masonry shells, represented in arches, domes, and vaults, leverage the strength of materials like Adobe in compression. Yet Shell construction has some challenges while using additive manufacturing such as; the increased material stress, posing potential issues like tensile stress, bending moments compared to standard vertical walls, and the need for supports/formworks at the cantilever spots. The paper aims to identify a strategy of geometries and self-supporting systems capable of sustaining compression forces under gravity loading without formwork with earthen-based material using 3d printing ( 3DP). To address this limitation, the paper presents a streamlined approach following a strategy that defines the optimized rib position and size to reinforce shells with dynamic behavior that changes according to stress simulations of self-supporting structure, this resulted, an enhanced resilience to external loads and lightweight structure. Several factors affect the optimal reinforcement of shell geometry, such as external loads, surface boundaries, and shape. The method followed used “Ameba” and “millipede” topological optimization tools based on BESO: "Bi-directional Evolutionary Structural Optimization", SIMP: "Solid Isotropic Material with Penalization" methods to showcases the optimum self-supporting system based on directional stress within optimum geometry simulation and mass customization. Utilizing Abaqus voxel-based simulation to simulate displacement in the layer 3DP process and (FEA) finite element analysis that integrates into existing computational frameworks, dynamically reshaping the initial design domain after iterative optimization cycle of the rib across diverse shapes, illustrating enhancements in reducing compliance (strain energy) of 3D-printed objects by defining the optimal amplitude and rib cross-section.