TY - CHAP A1 - Lange, Jörg A1 - Feucht, Thilo ED - Kuhlmann, Ulrike T1 - 3D‐Druck T2 - Stahlbau‐Kalender 2025: Neue Normen, Leichtmetallbau, Digitales Planen und Bauen UR - https://doi.org/10.1002/9783433612125.ch10 Y1 - 2025 UR - https://doi.org/10.1002/9783433612125.ch10 SN - 978-3-433-61212-5 VL - 27. Jahrgang SP - 817 EP - 858 PB - Ernst & Sohn CY - Berlin ER - TY - JOUR A1 - Feucht, Thilo A1 - Lange, Jörg A1 - Erven, Maren T1 - 3‐D‐Printing with Steel BT - Additive Manufacturing of Connection Elements and Beam Reinforcements JF - ce/papers: Proceedings in Civil Engineering UR - https://doi.org/10.1002/cepa.1064 Y1 - 2019 UR - https://doi.org/10.1002/cepa.1064 SN - 2509-7075 VL - 3 IS - 3-4 SP - 343 EP - 348 PB - Ernst & Sohn CY - Berlin ER - TY - CHAP A1 - Lange, Jörg A1 - Feucht, Thilo ED - Hofstadler, Christian ED - Motzko, Christoph T1 - Agiles Projektmanagement am Beispiel des 3D-Druckens im Stahlbau T2 - Agile Digitalisierung im Baubetrieb: Grundlagen, Innovationen, Disruptionen und Best Practices UR - https://doi.org/10.1007/978-3-658-34107-7_27 Y1 - 2021 UR - https://doi.org/10.1007/978-3-658-34107-7_27 SN - 978-3-658-34107-7 SP - 563 EP - 588 PB - Springer Vieweg CY - Wiesbaden ER - TY - JOUR A1 - Lange, Jörg A1 - Feucht, Thilo A1 - Erven, Maren A1 - Waldschmitt, Benedikt A1 - Oechsner, Matthias A1 - Klein, Marcus A1 - Schudlich, Anna‐Katharina T1 - 3D‐Druck im Stahlbau – additive Fertigung von Details, Verbindungen und Bauteilen JF - Stahlbau UR - https://doi.org/10.1002/stab.202000082 Y1 - 2020 UR - https://doi.org/10.1002/stab.202000082 SN - 1437-1049 VL - 89 IS - 12 SP - 981 EP - 991 PB - Ernst & Sohn CY - Berlin ER - TY - CHAP A1 - Feucht, Thilo A1 - Lange, Jörg A1 - Waldschmitt, Benedikt A1 - Schudlich, Anna‐Katharina A1 - Klein, Marcus A1 - Oechsner, Matthias ED - da Silva, Lucas F. M. ED - Martins, Paulo A. F. ED - El-Zein, Mohamad S. T1 - Welding Process for the Additive Manufacturing of Cantilevered Components with the WAAM T2 - Advanced Joining Processes UR - https://doi.org/10.1007/978-981-15-2957-3_5 Y1 - 2020 UR - https://doi.org/10.1007/978-981-15-2957-3_5 SN - 978-981-15-2957-3 SP - 67 EP - 78 PB - Springer CY - Singapore ER - TY - JOUR A1 - Erven, Maren A1 - Lange, Jörg A1 - Feucht, Thilo T1 - 3D‐Printing with steel of a bolted connection JF - ce/papers: Proceedings in Civil Engineering N2 - 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. UR - https://doi.org/10.1002/cepa.1367 Y1 - 2021 UR - https://doi.org/10.1002/cepa.1367 UR - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:bvb:573-58574 SN - 2509-7075 VL - 4 IS - 2-4 SP - 825 EP - 832 PB - Ernst & Sohn CY - Berlin ER - TY - JOUR A1 - Feucht, Thilo A1 - Lange, Jörg A1 - Erven, Maren A1 - Costanzi, Christopher Borg A1 - Knaack, Ulrich A1 - Waldschmitt, Benedikt T1 - Additive manufacturing by means of parametric robot programming JF - Construction Robotics N2 - 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. UR - https://doi.org/10.1007/s41693-020-00033-w Y1 - 2020 UR - https://doi.org/10.1007/s41693-020-00033-w UR - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:bvb:573-58610 SN - 2509-8780 VL - 4 IS - 1-2 SP - 31 EP - 48 PB - Springer CY - Cham ER - TY - JOUR A1 - Lange, Jörg A1 - Feucht, Thilo A1 - Erven, Maren T1 - 3D printing with steel BT - Additive Manufacturing for connections and structures JF - Steel Construction: Design and Research N2 - 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. UR - https://doi.org/10.1002/stco.202000031 Y1 - 2020 UR - https://doi.org/10.1002/stco.202000031 UR - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:bvb:573-58602 SN - 1867-0539 VL - 13 IS - 3 SP - 144 EP - 153 PB - Ernst & Sohn CY - Berlin ER - TY - JOUR A1 - Feucht, Thilo A1 - Waldschmitt, Benedikt A1 - Lange, Jörg A1 - Erven, Maren T1 - 3D‐Printing with Steel: Additive Manufacturing of a Bridge in situ JF - ce/papers: Proceedings in Civil Engineering N2 - 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. UR - https://doi.org/10.1002/cepa.1475 Y1 - 2021 UR - https://doi.org/10.1002/cepa.1475 UR - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:bvb:573-58562 SN - 2509-7075 VL - 4 IS - 2-4 SP - 1695 EP - 1701 PB - Ernst & Sohn CY - Berlin ER - TY - JOUR A1 - Feucht, Thilo A1 - Waldschmitt, Benedikt A1 - Lange, Jörg A1 - Erven, Maren T1 - Additive manufacturing of a bridge in situ JF - Steel Construction: Design and Research N2 - 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. UR - https://doi.org/10.1002/stco.202100045 Y1 - 2022 UR - https://doi.org/10.1002/stco.202100045 UR - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:bvb:573-58548 SN - 1867-0539 VL - 15 IS - 2 SP - 100 EP - 110 PB - Ernst & Sohn CY - Berlin ER - TY - JOUR A1 - Lange, Jörg A1 - Feucht, Thilo A1 - Erven, Maren T1 - 3D‐Printing with Steel ‐ Additive Manufacturing Connections and Structures JF - ce/papers: Proceedings in Civil Engineering N2 - 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. UR - https://doi.org/10.1002/cepa.1258 Y1 - 2021 UR - https://doi.org/10.1002/cepa.1258 UR - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:bvb:573-58559 SN - 2509-7075 VL - 4 IS - 2-4 SP - 2 EP - 7 PB - Ernst & Sohn CY - Berlin ER - TY - THES A1 - Feucht, Thilo T1 - Additive Fertigung von Anschlusselementen im Stahlbau mit dem Wire Arc Additive Manufacturing N2 - In dieser Arbeit wird untersucht, wie stahlbauübliche Anschlusselemente mittels Wire Arc Additive Manufacturing (WAAM) gefertigt werden können. Die Motivation liegt darin, die heutzutage weiterhin übliche händische und zeitaufwendige Baugruppenfertigung durch einen vollautomatisierten Produktionsschritt zu ersetzen, indem die Anschlusselemente direkt auf Stahlträger additiv gefertigt werden. Die Grundlagen und Besonderheiten des WAAM werden dafür erläutert und beschrieben. Zur Ermöglichung eines WAAM-gerechten Konstruierens werden Lehrsätze im Sinne einer wissenschaftlichen Aussage formuliert. Mit dem präsentierten 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 (Trägerhaken, Lasteinleitungssteife, Spannelement) werden bespielhaft optimiert. Im darauffolgenden Kapitel werden für jene Anschlusselemente geeignete Fertigungsstrategien erarbeitet und die Fertigung mit dem WAAM beschrieben. Die Tragfähigkeit der Anschlusselemente wird in zerstörenden Versuchen ermittelt und abschließend in einem Auswertungskapitel mit den numerischen Tragfähigkeiten verglichen. N2 - In this thesis it is investigated how common connection-elements in steel-construction can be manufactured by means of Wire Arc Additive Manufacturing (WAAM). The idea was to replace the manual and time-consuming assembly process, which is still common today, by a fully-automated manufacturing-step through additively manufacturing the connection elements directly onto the steel beams. The basics and particularities of WAAM are explained and described. To enable WAAM-compatible design, theorems as science-based statements are formulated. With the 8-step optimization process presented in this work, the structures of the connection-elements are determined. This ensures that the material is statically optimally utilized while a fast and error-free manufacturing process is guaranteed. Numerical topology-optimization and numerical ultimate-load analysis are used in the optimization process. For practical demonstration, three connection elements (beam hook, load-introduction stiffener, clamping element) are optimized. In a following chapter, suitable manufacturing strategies for these connection elements are outlined. The manufacturing process with the WAAM is described. The ultimate load-capacity of the connection elements is determined via destructive tests. In an evaluation chapter, the outcomes of these tests are compared with the numerical ultimate load-capacities. UR - https://doi.org/10.26083/tuprints-00024363 Y1 - 2023 UR - https://doi.org/10.26083/tuprints-00024363 UR - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:bvb:573-57507 PB - Technische Universität Darmstadt CY - Darmstadt ER - TY - CHAP A1 - Feucht, Thilo A1 - Lange, Jörg ED - Zingoni, Alphose T1 - 3-D-printing with steel: Additive manufacturing of connection elements T2 - 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) UR - https://doi.org/10.1201/9780429426506-75 Y1 - 2019 UR - https://doi.org/10.1201/9780429426506-75 SN - 978-0-429-42650-6 SP - 419 EP - 424 PB - Taylor & Francis CY - London ER -