Exploring 3D printing techniques for the hybrid fabrication of discrete topology optimized structures

The application of topology optimization methods in architecture, while useful for conceptual design explorations, seems to be limited by the practical realization of continuum-type design outcomes. One way to overcome this limitation is setting up design and fabrication techniques, through which continuum domains become discrete structures. This study investigates to which extent discrete optimized systems can be built using a hybrid approach combining 3D printing and analogue fabrication techniques. The procedure is based on an algorithm in Grasshopper (Rhinoceros) that translates continuum topologies obtained in MATLAB into discrete systems, providing alternatives depending on the targeted volume fraction, the intended surface smoothness of the structural components and building material. The study focuses on fabrication aspects and structural performance of discrete structures using 3D printed nodes. Experimental tests evaluate the compressive strength of different types of filaments with varied infill percentages. Final prototypes are fabricated using a hybrid technique involving the use of 3D printed nodes to assemble bar-arrays comprising wooden members. Results provide a critical appraisal of the limitations and potentialities of 3D printing for hybrid fabrication of real scale structures.