@inbook{LangeFeucht2025, author = {Lange, J{\"o}rg and Feucht, Thilo}, title = {3D-Druck}, volume = {27. Jahrgang}, booktitle = {Stahlbau-Kalender 2025: Neue Normen, Leichtmetallbau, Digitales Planen und Bauen}, editor = {Kuhlmann, Ulrike}, publisher = {Ernst \& Sohn}, address = {Berlin}, isbn = {978-3-433-61212-5}, doi = {https://doi.org/10.1002/9783433612125.ch10}, pages = {817 -- 858}, year = {2025}, language = {de} } @article{FeuchtLangeErven2019, author = {Feucht, Thilo and Lange, J{\"o}rg and Erven, Maren}, title = {3-D-Printing with Steel}, volume = {3}, journal = {ce/papers: Proceedings in Civil Engineering}, subtitle = {Additive Manufacturing of Connection Elements and Beam Reinforcements}, number = {3-4}, publisher = {Ernst \& Sohn}, address = {Berlin}, issn = {2509-7075}, doi = {https://doi.org/10.1002/cepa.1064}, pages = {343 -- 348}, year = {2019}, language = {en} } @inbook{LangeFeucht2021, author = {Lange, J{\"o}rg and Feucht, Thilo}, title = {Agiles Projektmanagement am Beispiel des 3D-Druckens im Stahlbau}, booktitle = {Agile Digitalisierung im Baubetrieb: Grundlagen, Innovationen, Disruptionen und Best Practices}, editor = {Hofstadler, Christian and Motzko, Christoph}, publisher = {Springer Vieweg}, address = {Wiesbaden}, isbn = {978-3-658-34107-7}, doi = {https://doi.org/10.1007/978-3-658-34107-7_27}, pages = {563 -- 588}, year = {2021}, language = {de} } @article{LangeFeuchtErvenetal.2020, author = {Lange, J{\"o}rg and Feucht, Thilo and Erven, Maren and Waldschmitt, Benedikt and Oechsner, Matthias and Klein, Marcus and Schudlich, Anna-Katharina}, title = {3D-Druck im Stahlbau - additive Fertigung von Details, Verbindungen und Bauteilen}, volume = {89}, journal = {Stahlbau}, number = {12}, publisher = {Ernst \& Sohn}, address = {Berlin}, issn = {1437-1049}, doi = {https://doi.org/10.1002/stab.202000082}, pages = {981 -- 991}, year = {2020}, language = {de} } @inbook{FeuchtLangeWaldschmittetal.2020, author = {Feucht, Thilo and Lange, J{\"o}rg and Waldschmitt, Benedikt and Schudlich, Anna-Katharina and Klein, Marcus and Oechsner, Matthias}, title = {Welding Process for the Additive Manufacturing of Cantilevered Components with the WAAM}, booktitle = {Advanced Joining Processes}, editor = {da Silva, Lucas F. M. and Martins, Paulo A. F. and El-Zein, Mohamad S.}, publisher = {Springer}, address = {Singapore}, isbn = {978-981-15-2957-3}, doi = {https://doi.org/10.1007/978-981-15-2957-3_5}, pages = {67 -- 78}, year = {2020}, language = {en} } @article{ErvenLangeFeucht2021, author = {Erven, Maren and Lange, J{\"o}rg and Feucht, Thilo}, title = {3D-Printing with steel of a bolted connection}, volume = {4}, journal = {ce/papers: Proceedings in Civil Engineering}, number = {2-4}, publisher = {Ernst \& Sohn}, address = {Berlin}, issn = {2509-7075}, doi = {https://doi.org/10.1002/cepa.1367}, pages = {825 -- 832}, year = {2021}, abstract = {Additive Manufacturing seems promising for the steel construction industry, especially for small components with complex shapes. With Wire-and-Arc-Additive-Manufacturing (WAAM) a process was found which is fast and cheap compared to other Additive Manufacturing processes for metals. Furthermore, arc-welding is well known in steel construction industry.Bolted head plates are a common connection. Although they are relatively easy to produce, they are uneconomical in load transfer due to straining of the plates which are subject to bending. This type of connection is predestined for Additive Manufacturing. Rethinking the structure by taking into account the potentials of Additive Manufacturing brings a clear advantage compared to the conventional production. Thus, with a material saving of 60 \% the same load capacity of the original flat head plate can be achieved.The paper shows how the new production process WAAM can significantly change the shape of structures on the example of a bolted head plate. Therefore, all steps from the original design to the manufactured structure are demonstrated, including the structure finding by using topology optimization, the manufacturing with different parameters and a first testing of the manufactured structures.}, language = {en} } @article{FeuchtLangeErvenetal.2020, author = {Feucht, Thilo and Lange, J{\"o}rg and Erven, Maren and Costanzi, Christopher Borg and Knaack, Ulrich and Waldschmitt, Benedikt}, title = {Additive manufacturing by means of parametric robot programming}, volume = {4}, journal = {Construction Robotics}, number = {1-2}, publisher = {Springer}, address = {Cham}, issn = {2509-8780}, doi = {https://doi.org/10.1007/s41693-020-00033-w}, pages = {31 -- 48}, year = {2020}, abstract = {3D printing or additive manufacturing (AM) is now becoming a common technology in industry. The research activities in this area are constantly increasing, because with the high level of automation and the possibility to produce individual and complex structures, the advantages of additive manufacturing are promising. Most materials used in the construction industry can be used for additive manufacturing, for example steel and concrete. The print head (for example, a welding torch in the AM of steel) is mainly led by industrial robots, whose movements must be transferred from the 3D geometry files to be manufactured. In contrast to all-in-one systems, where hardware, software and printed material are coordinated, most robot-based AM systems are made of components from different manufacturers and branches. The objects to be manufactured are complex and the manufacturing parameters, which significantly influence the geometry and quality of the manufactured part, are manifold. This makes the workflow from the 3D model to the finished object difficult, especially because it is almost impossible to predict the exact manufactured structure geometry or layer height (which would be indispensable for accurate slicing). During the manufacturing process, deviations between the target and actual geometry can occur. In this paper, parametric robot programming (PRP) is presented, which allows flexible motion programming, and a quick and easy reaction to deviations between target and actual geometry during the manufacturing process. Complex geometries are divided into iso-curves whose mathematical functions are determined by means of polynomial regression. The robot can calculate the coordinates to be approached from these functions itself. This allows a simple adjustment of the manufacturing coordinates during the process as soon as target-actual deviations occur. The workflow from the file to the manufactured object is explained. The principle of PRP is transferable and applicable to all robot manufacturers and all conceivable printing processes. In the following article, it will be presented using wire + arc additive manufacturing, in which welding robots or portals can be used to produce steel structures with high deposition rates. Furthermore, the project "AM Bridge 2019" is presented, in which a steel bridge was manufactured in situ over a little creek and the presented PRP was applied.}, language = {en} } @article{LangeFeuchtErven2020, author = {Lange, J{\"o}rg and Feucht, Thilo and Erven, Maren}, title = {3D printing with steel}, volume = {13}, journal = {Steel Construction: Design and Research}, subtitle = {Additive Manufacturing for connections and structures}, number = {3}, publisher = {Ernst \& Sohn}, address = {Berlin}, issn = {1867-0539}, doi = {https://doi.org/10.1002/stco.202000031}, pages = {144 -- 153}, year = {2020}, abstract = {Automated production is finding its way into the fabrication of structural steel. One robot holds attachments (stiffeners, end plates, etc.) on a steel beam or column and another robot produces weld seams. However, welding robots can also be used for Additive Manufacturing (Wire and Arc Additive Manufacturing, WAAM). The wire electrode serves as a printing material. The Institute of Steel Construction and Materials Mechanics in Darmstadt is investigating how typical connecting elements for steel structures can be printed directly on steel beams using Additive Manufacturing with arc welding and robots. Furthermore, structural elements such as nodes for space frames can be printed and even complete structures, e.g. columns and a little bridge, have already been manufactured additively. The main focus is on determining suitable welding and process parameters. In addition, topology optimization is necessary in order to achieve good structures using a small amount of material. This is possible due to the free design prospects of WAAM, which opens up new design and production strategies.}, language = {en} } @article{FeuchtWaldschmittLangeetal.2021, author = {Feucht, Thilo and Waldschmitt, Benedikt and Lange, J{\"o}rg and Erven, Maren}, title = {3D-Printing with Steel: Additive Manufacturing of a Bridge in situ}, volume = {4}, journal = {ce/papers: Proceedings in Civil Engineering}, number = {2-4}, publisher = {Ernst \& Sohn}, address = {Berlin}, issn = {2509-7075}, doi = {https://doi.org/10.1002/cepa.1475}, pages = {1695 -- 1701}, year = {2021}, abstract = {Additive manufacturing (AM) plays an increasing role in the production of complex structures in steel construction. Robot-guided Gas Shielded Metal Arc Welding (GMAW), known as Wire and Arc Additive Manufacturing (WAAM), is suitable for this purpose. At TU Darmstadt, a small pedestrian bridge in shell form was designed. It was completely additively manufactured on site with a welding robot over a creek. This paper presents selected aspects of this project. The focus is particularly on the preliminary strength investigations carried out and the process sequences required for homogenous manufacturing. The paper concludes with a consideration of the implementation on site.}, language = {en} } @article{FeuchtWaldschmittLangeetal.2022, author = {Feucht, Thilo and Waldschmitt, Benedikt and Lange, J{\"o}rg and Erven, Maren}, title = {Additive manufacturing of a bridge in situ}, volume = {15}, journal = {Steel Construction: Design and Research}, number = {2}, publisher = {Ernst \& Sohn}, address = {Berlin}, issn = {1867-0539}, doi = {https://doi.org/10.1002/stco.202100045}, pages = {100 -- 110}, year = {2022}, abstract = {Additive manufacturing (AM) is playing an increasing role in the production of complex steel structures. Robot- or machine-guided gas-shielded metal arc welding (GMAW), known as wire and arc additive manufacturing (WAAM), is suitable for this purpose. A small footbridge was designed in shell form at TU Darmstadt. It was completely additively manufactured over a stream on site using a welding robot. The work called for cantilevered manufacturing without support structures, which poses special challenges in manufacturing. This paper describes selected aspects of this project: the preliminary strength studies, the manufacturing strategy to ensure homogeneous manufacturing and the findings from on-site manufacturing. In addition, investigations were carried out which led to a notable increase in the deposition rate with the right choice of gas and wire.}, language = {en} } @article{LangeFeuchtErven2021, author = {Lange, J{\"o}rg and Feucht, Thilo and Erven, Maren}, title = {3D-Printing with Steel - Additive Manufacturing Connections and Structures}, volume = {4}, journal = {ce/papers: Proceedings in Civil Engineering}, number = {2-4}, publisher = {Ernst \& Sohn}, address = {Berlin}, issn = {2509-7075}, doi = {https://doi.org/10.1002/cepa.1258}, pages = {2 -- 7}, year = {2021}, abstract = {Automated production is finding its way into fabrication of structural steel. One robot holds attachments (stiffeners, head plates, etc.) to a steel beam or column and another robot produces weld seams. However, welding robots can also be used for additive manufacturing (Wire + Arc Additive Manufacturing, WAAM). The wire electrode serves as printing material. The Institute for Steel Construction and Materials Mechanics in Darmstadt is investigating how typical connecting elements of steel construction can be printed directly on steel beams using Additive Manufacturing with arc welding and robots. Furthermore structural elements like nodal points are printed and even complete structures like columns and a little bridge have been manufactured additively already. The main focus is on determining suitable welding and process parameters. In addition, topology optimization is used to find good structures using a low amount of material. This is possible due to the free design prospects of 3D-printing. This opens for novel design and production strategies.}, language = {en} } @phdthesis{Feucht2023, author = {Feucht, Thilo}, title = {Additive Fertigung von Anschlusselementen im Stahlbau mit dem Wire Arc Additive Manufacturing}, publisher = {Technische Universit{\"a}t Darmstadt}, address = {Darmstadt}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:573-57507}, pages = {196 Seiten in verschiedenen Z{\"a}hlungen}, school = {Technische Universit{\"a}t Darmstadt}, year = {2023}, abstract = {In dieser Arbeit wird untersucht, wie stahlbau{\"u}bliche Anschlusselemente mittels Wire Arc Additive Manufacturing (WAAM) gefertigt werden k{\"o}nnen. Die Motivation liegt darin, die heutzutage weiterhin {\"u}bliche h{\"a}ndische und zeitaufwendige Baugruppenfertigung durch einen vollautomatisierten Produktionsschritt zu ersetzen, indem die Anschlusselemente direkt auf Stahltr{\"a}ger additiv gefertigt werden. Die Grundlagen und Besonderheiten des WAAM werden daf{\"u}r erl{\"a}utert und beschrieben. Zur Erm{\"o}glichung eines WAAM-gerechten Konstruierens werden Lehrs{\"a}tze im Sinne einer wissenschaftlichen Aussage formuliert. Mit dem pr{\"a}sentierten 8-schrittigen Optimierungsprozess werden die Strukturen der Anschlusselemente ermittelt, sodass das Material statisch optimal ausgenutzt wird und gleichzeitig eine schnelle und fehlerfreie Fertigung gelingt. Im Optimierungsprozess werden die numerische Topologieoptimerung sowie die numerische Traglastanalyse genutzt. Drei Anschlusselemente (Tr{\"a}gerhaken, Lasteinleitungssteife, Spannelement) werden bespielhaft optimiert. Im darauffolgenden Kapitel werden f{\"u}r jene Anschlusselemente geeignete Fertigungsstrategien erarbeitet und die Fertigung mit dem WAAM beschrieben. Die Tragf{\"a}higkeit der Anschlusselemente wird in zerst{\"o}renden Versuchen ermittelt und abschließend in einem Auswertungskapitel mit den numerischen Tragf{\"a}higkeiten verglichen.}, language = {de} } @inproceedings{FeuchtLange2019, author = {Feucht, Thilo and Lange, J{\"o}rg}, title = {3-D-printing with steel: Additive manufacturing of connection elements}, booktitle = {Advances in Engineering Materials, Structures and Systems: Innovations, Mechanics and Applications, Proceedings of the 7th International Conference on Structural Engineering, Mechanics and Computation (SEMC 2019)}, editor = {Zingoni, Alphose}, publisher = {Taylor \& Francis}, address = {London}, isbn = {978-0-429-42650-6}, doi = {https://doi.org/10.1201/9780429426506-75}, pages = {419 -- 424}, year = {2019}, language = {en} }