Development of an expert system based on fuzzy logic as support for heat pipes design

Heat pipe design and selection require specialist knowledge due to numerous possible combinations and restrictions that should be considered. The general objective of this work is to design a Specialist System that assists future engineers in material and working fluid selection for a suitable heat pipe application, based on the technical operating requirements. The methodology consisted of a qualitative perspective through interviews with two specialist engineers in the heat pipes area. The resulting information from the interviews was organized into a library, working as a source for the specialist system. In addition, several books from the literature completed the information in the library. Based on the operating conditions and the provided library, the program recommends suitable materials and working fluids and the necessity of porous media for the application, like a consult with a heat pipe specialist. The new expert system can be a tool for researchers and engineers in heat pipe design as passive control systems, providing more suitable solutions for each application

Unveiling the third dimension of glass

Glass as a material has always fascinated architects. Its inherent transparency has given us the ability to create diaphanous barriers between the interior and the exterior that allow for space and light continuity. Yet, we are just starting to understand the full potential, properties and characteristics of glass as a material. Only in the last decades did we discover the structural potential of glass and started to use it, besides as a cladding material, also for load-bearing applications thanks to its high compressive strength. Indeed, at present the structural applications of glass in architecture are continuously increasing, yet they are dominated by a considerable geometrical limitation: the essentially 2-dimensionality imposed by the prevailing float glass industry. Although glass panels can stretch more than 20 m in length, the maximum monolithic thickness by this manufacturing method remains a mere 25 mm. As a result glass structures are currently dominated by virtually 2-dimensional, planar elements and confined to the limited shapes that can be achieved by those. This research focuses on the exploration of cast glass as a promising, 3-dimensional construction material in architecture. The main aim of this research is therefore to investigate the potential, as well as the constraints, of cast glass components for the engineering of transparent, 3-dimensional glass structures in architecture. By pouring molten glass into moulds, solid 3-dimensional glass components of virtually any shape and cross-section can be made. Owing to their monolithic nature, such components can form repetitive units for the construction of freeform, full-glass structures that are not sensitive to buckling. Such structures can take full advantage of the high compressive strength of glass, sparing the necessity of additional supporting elements. To achieve cast glass structures, it is essential to use an intermediate material between the individual glass components that contributes to the structure’s stiffness, ensures a homogeneous load distribution and prevents early failure due to concentrated stresses triggered by glass-to-glass contact. To maximize transparency, this intermedium should be colourless and any additional substructure should be minimized. Accordingly, the main scientific contribution of this research work is the design, development and experimental investigation of two distinct systems for selfsupporting envelopes of maximized transparency: An adhesively bonded glass block system, using a colourless adhesive as an intermedium and a dry-assembly, interlocking cast glass block system, employing a colourless dry interlayer. Although, in this work, both systems have been developed for self-supporting envelopes, the results can be used as a guideline for further structural applications of cast glass components in compressive elements, such as columns, arches and bending elements, such as beams and fins. At present, the load-bearing function of cast glass in architecture remains an uncharted field. Discouraging factors such as the lengthy annealing process required, the to-date non-standardized production and the corresponding high manufacturing costs, have limited cast glass to only a few realized architectural applications. As a result, there is a lack of engineering data and a general unawareness of the potential and risks of employing cast glass structurally. Hence, in order to accomplish the research goal, all pertinent aspects of a cast glass structure should be tackled, ranging from cast glass’s production method to practical implications when building with cast glass. These distinct aspects are addressed through the formulation of the research sub-questions, which in turn define the different chapters of this dissertation. Accordingly, the presented work is divided in four parts. Part I provides the Introduction to the Research, and aims at giving a brief summary of the involved challenges, identify the research gap and introduce the research questions and the research methodology.  Part II focuses on the Theoretical Framework of the Research. It lays the foundations for this dissertation and contributes to the scientific field of structural glass by providing the first comprehensive literature review and state-of-the art overview of cast glass structural applications. Initially, the material compositions and production methods for solid cast glass components are explored. Then, to address both possibilities and limitations in the size and form of cast glass components, an overview and critical assessment of the largest produced monolithic pieces of cast glass is made. Given the limited published scientific output on this specific field, an extensive field research was conducted in order to derive the relevant data. The discussed examples, although coming from different fields of science and art, provide great insight into the practical implications involved in casting as a manufacturing method. Subsequently, a separate chapter gives an overview of the state-ofthe- art in cast glass structural applications in architecture. Aiming on providing the reader with an holistic overview of the structural potential of cast glass in architectural applications, this chapter includes the synopsis, feasibility assessment and comparison of not only the realized structural design systems but also of the adhesively-bonded and dry-assembly interlocking systems developed in this dissertation. Special attention is given to the advantages and disadvantages of the connection method of each -existing and developed in this dissertation- structural design system with solid glass blocks. Following the findings of the literature review and field research, Part III, consisting of four chapters, presents the design and experimental investigation of two distinct, novel structural systems out of cast glass components, developed for selfsupporting envelopes. Part III can be considered the main scientific outcome of this dissertation. Firstly, the research, development and experimental validation of an adhesively bonded system utilizing solid cast glass blocks is presented. Numerous full-scale prototypes are made and tested in order to comprehend the structural behaviour of the adhesively bonded glass assembly. A separate chapter explores the main challenges and innovations and defines the construction requirements necessary for the realization of the investigated system at the Crystal Houses Façade in Amsterdam. An important conclusion is that such an adhesively bonded system requires an extremely high dimensional accuracy both in the fabrication of the glass blocks and in the entire construction, and has an irreversible nature, which in turn results in a meticulous and unsustainable construction. Based on the aforementioned challenges, a new concept for glass structures out of dry-assembled interlocking cast glass components is developed that tackles the integral limitations of the adhesively-bonded system. An entire chapter is dedicated to the principles, the establishment of design criteria and to the preliminary exploration and assessment of different interlocking cast glass shapes that can yield an interlocking cast glass system of satisfactory structural performance. Following, the last chapter of this part concerns the experimental and numerical investigation of this second system. The effect of various parameters in the structural behaviour of the system is explored through the production of scaled prototypes and their experimental validation. A numerical model further explores the correlation of the various geometrical parameters of the interlocking geometry to the structural behaviour of the system. Finally, Part IV presents an integrated discussion of the research results, summarizing and discussing the main outcomes of the dissertation. Initially, responses to the research questions are given in order to assess the particular findings. Based on the conclusions, further recommendations are made, firstly for overcoming the limitations of the presented research, following by general suggestions on a wider range of the aspects of cast glass that can be explored and contribute to its structural applicability. The findings of this dissertation prove the feasibility of the discussed systems and can serve as solid guidelines for further applications. The research presented in this work has been positively received by the international architectural and engineering community. In specific, the presented adhesivelybonded cast block system, which was realized at the Crystal Houses façade, received numerous awards by the structural engineering community, including the Outstanding Innovation Award 2016 by the Society of Façade Engineers and the Glass Innovation Award 2016 from the Bouwend Nederland association. Still, the Crystal Houses façade is but the first real-scale prototype of the developed adhesively bonded system. The actual construction of the façade provided invaluable feedback on the engineering challenges and construction requirements involved in such a system, giving room for new suggestions. This triggered the development of the second presented system with interlocking glass blocks as a reversible, easily assembled solution. The interlocking cast glass block system, initiated within TU Delft and funded partially by a 4TU.bouw grant is yet to be applied in practice. Prototypes of this research, using recycled cast glass components, have been exhibited in international fairs such as the Venice Design 2018, the Dutch Design Week 2018 and Salone del Mobile 2019 and are currently displayed at the material collection of the Vitra Design Museum at the Vitra Schaudepot. The project was also nominated for the New Material Award 2018 under the title Re3 Glass. Even though cast glass has, so far, been rarely applied in structural applications, the development of new building systems and their experimental validation presented in this work provide a strong basis for further developments and applications in a range of compressive structures. At present, the most considerable drawbacks hindering the marketability of cast glass components are (a) the cost barriers imposed by their customized production and application and (b) the lack of standardized strength data and building guidelines. Thus, even if cast glass elements have proved to be suitable structural components, several economic aspects and logistics need to be tackled, and performance issues need to be further explored, in order to make cast glass a competitive manufacturing method to float production for structural components

Unveiling the third dimension of glass:

Glass as a material has always fascinated architects. Its inherent transparency has given us the ability to create diaphanous barriers between the interior and the exterior that allow for space and light continuity. Yet, we are just starting to understand the full potential, properties and characteristics of glass as a material. Only in the last decades did we discover the structural potential of glass and started to use it, besides as a cladding material, also for load-bearing applications thanks to its high compressive strength. Indeed, at present the structural applications of glass in architecture are continuously increasing, yet they are dominated by a considerable geometrical limitation: the essentially 2-dimensionality imposed by the prevailing float glass industry. Although glass panels can stretch more than 20 m in length, the maximum monolithic thickness by this manufacturing method remains a mere 25 mm. As a result glass structures are currently dominated by virtually 2-dimensional, planar elements and confined to the limited shapes that can be achieved by those. This research focuses on the exploration of cast glass as a promising, 3-dimensional construction material in architecture. The main aim of this research is therefore to investigate the potential, as well as the constraints, of cast glass components for the engineering of transparent, 3-dimensional glass structures in architecture. By pouring molten glass into moulds, solid 3-dimensional glass components of virtually any shape and cross-section can be made. Owing to their monolithic nature, such components can form repetitive units for the construction of freeform, full-glass structures that are not sensitive to buckling. Such structures can take full advantage of the high compressive strength of glass, sparing the necessity of additional supporting elements. To achieve cast glass structures, it is essential to use an intermediate material between the individual glass components that contributes to the structure’s stiffness, ensures a homogeneous load distribution and prevents early failure due to concentrated stresses triggered by glass-to-glass contact. To maximize transparency, this intermedium should be colourless and any additional substructure should be minimized. Accordingly, the main scientific contribution of this research work is the design, development and experimental investigation of two distinct systems for selfsupporting envelopes of maximized transparency: An adhesively bonded glass block system, using a colourless adhesive as an intermedium and a dry-assembly, interlocking cast glass block system, employing a colourless dry interlayer. Although, in this work, both systems have been developed for self-supporting envelopes, the results can be used as a guideline for further structural applications of cast glass components in compressive elements, such as columns, arches and bending elements, such as beams and fins. At present, the load-bearing function of cast glass in architecture remains an uncharted field. Discouraging factors such as the lengthy annealing process required, the to-date non-standardized production and the corresponding high manufacturing costs, have limited cast glass to only a few realized architectural applications. As a result, there is a lack of engineering data and a general unawareness of the potential and risks of employing cast glass structurally. Hence, in order to accomplish the research goal, all pertinent aspects of a cast glass structure should be tackled, ranging from cast glass’s production method to practical implications when building with cast glass. These distinct aspects are addressed through the formulation of the research sub-questions, which in turn define the different chapters of this dissertation. Accordingly, the presented work is divided in four parts. Part I provides the Introduction to the Research, and aims at giving a brief summary of the involved challenges, identify the research gap and introduce the research questions and the research methodology.  Part II focuses on the Theoretical Framework of the Research. It lays the foundations for this dissertation and contributes to the scientific field of structural glass by providing the first comprehensive literature review and state-of-the art overview of cast glass structural applications. Initially, the material compositions and production methods for solid cast glass components are explored. Then, to address both possibilities and limitations in the size and form of cast glass components, an overview and critical assessment of the largest produced monolithic pieces of cast glass is made. Given the limited published scientific output on this specific field, an extensive field research was conducted in order to derive the relevant data. The discussed examples, although coming from different fields of science and art, provide great insight into the practical implications involved in casting as a manufacturing method. Subsequently, a separate chapter gives an overview of the state-ofthe- art in cast glass structural applications in architecture. Aiming on providing the reader with an holistic overview of the structural potential of cast glass in architectural applications, this chapter includes the synopsis, feasibility assessment and comparison of not only the realized structural design systems but also of the adhesively-bonded and dry-assembly interlocking systems developed in this dissertation. Special attention is given to the advantages and disadvantages of the connection method of each -existing and developed in this dissertation- structural design system with solid glass blocks. Following the findings of the literature review and field research, Part III, consisting of four chapters, presents the design and experimental investigation of two distinct, novel structural systems out of cast glass components, developed for selfsupporting envelopes. Part III can be considered the main scientific outcome of this dissertation. Firstly, the research, development and experimental validation of an adhesively bonded system utilizing solid cast glass blocks is presented. Numerous full-scale prototypes are made and tested in order to comprehend the structural behaviour of the adhesively bonded glass assembly. A separate chapter explores the main challenges and innovations and defines the construction requirements necessary for the realization of the investigated system at the Crystal Houses Façade in Amsterdam. An important conclusion is that such an adhesively bonded system requires an extremely high dimensional accuracy both in the fabrication of the glass blocks and in the entire construction, and has an irreversible nature, which in turn results in a meticulous and unsustainable construction. Based on the aforementioned challenges, a new concept for glass structures out of dry-assembled interlocking cast glass components is developed that tackles the integral limitations of the adhesively-bonded system. An entire chapter is dedicated to the principles, the establishment of design criteria and to the preliminary exploration and assessment of different interlocking cast glass shapes that can yield an interlocking cast glass system of satisfactory structural performance. Following, the last chapter of this part concerns the experimental and numerical investigation of this second system. The effect of various parameters in the structural behaviour of the system is explored through the production of scaled prototypes and their experimental validation. A numerical model further explores the correlation of the various geometrical parameters of the interlocking geometry to the structural behaviour of the system. Finally, Part IV presents an integrated discussion of the research results, summarizing and discussing the main outcomes of the dissertation. Initially, responses to the research questions are given in order to assess the particular findings. Based on the conclusions, further recommendations are made, firstly for overcoming the limitations of the presented research, following by general suggestions on a wider range of the aspects of cast glass that can be explored and contribute to its structural applicability. The findings of this dissertation prove the feasibility of the discussed systems and can serve as solid guidelines for further applications. The research presented in this work has been positively received by the international architectural and engineering community. In specific, the presented adhesivelybonded cast block system, which was realized at the Crystal Houses façade, received numerous awards by the structural engineering community, including the Outstanding Innovation Award 2016 by the Society of Façade Engineers and the Glass Innovation Award 2016 from the Bouwend Nederland association. Still, the Crystal Houses façade is but the first real-scale prototype of the developed adhesively bonded system. The actual construction of the façade provided invaluable feedback on the engineering challenges and construction requirements involved in such a system, giving room for new suggestions. This triggered the development of the second presented system with interlocking glass blocks as a reversible, easily assembled solution. The interlocking cast glass block system, initiated within TU Delft and funded partially by a 4TU.bouw grant is yet to be applied in practice. Prototypes of this research, using recycled cast glass components, have been exhibited in international fairs such as the Venice Design 2018, the Dutch Design Week 2018 and Salone del Mobile 2019 and are currently displayed at the material collection of the Vitra Design Museum at the Vitra Schaudepot. The project was also nominated for the New Material Award 2018 under the title Re3 Glass. Even though cast glass has, so far, been rarely applied in structural applications, the development of new building systems and their experimental validation presented in this work provide a strong basis for further developments and applications in a range of compressive structures. At present, the most considerable drawbacks hindering the marketability of cast glass components are (a) the cost barriers imposed by their customized production and application and (b) the lack of standardized strength data and building guidelines. Thus, even if cast glass elements have proved to be suitable structural components, several economic aspects and logistics need to be tackled, and performance issues need to be further explored, in order to make cast glass a competitive manufacturing method to float production for structural components

Failure load of monolithic and veneered Y-TZP and glass ceramic subjected to aging and fatigue

OBJECTIVES: Objectives of this study were to evaluate and compare the failure load and mode of failure of aged (4 years) monolithic and veneered Y-TZP and glass ceramic subjected to static loading, cyclic loading, and thermo-cycling. MATERIALS AND METHODS: 2 ceramic materials were used: Vita In-Ceram YZ and IPS e. max CAD. Each material was designed into 60 veneered copings and 30 monolithic crowns (180 specimens). 10 specimens per group were loaded under compression using an Instron universal testing machine at a rate of 0.5 mm/minute until fracture. Another 10 specimens were subjected to cyclic loading (chewing simulation) in a water bath for 50,000 cycles at a frequency of 1 Hz at 30% of the mean failure load, and then were loaded under compression to fracture. Another 10 specimens were subjected to a thermo-cycling test, then loaded under compression to fracture. Data were analyzed using the ANOVA test at α=0.05. RESULTS: The mean failure load (standard deviation) values for veneered zirconia and e.max CAD copings and monolithic zirconia and e.max CAD crowns under static loading were: In-Ceram YZ 14830 N (2494), VM9 2491 N (1047), PM9 3909 N (783), IPS e.max CAD 4197 N (1011), IPS e. max Ceram 1206 N (296), IPS e.max press 2949 N (710). The values for veneered standard zirconia and e.max CAD copings and monolithic zirconia and e.max CAD crowns after cyclic fatigue were: In-Ceram YZ 11039 N (2720), VM9 2849 N (840), PM9 3170 N (1156), IPS e.max CAD 3539 N (526), IPS e. max Ceram 1291 N (1051), IPS e.max press 3093 N (742). For veneered standard zirconia and e.max CAD copings and monolithic zirconia and e.max CAD crowns after thermo- cycling: In-Ceram YZ 15695 N (1517), VM9 3177 N (816), PM9 2860 N (783), IPS e.max CAD 4265 N (681), IPS e. max Ceram 1149 N (375), IPS e.max press 2832 N (717). There was a significant difference in failure load between veneered and monolithic ceramic crowns subjected to static loading, cyclic loading, and thermo-cycling, and a significant difference in the mode of failure between veneered or monolithic crowns. CONCLUSIONS: 1. There was a significant difference in the static failure load of different veneered (Hand layered and pressed-on) YTZP zirconia and e.max CAD copings, monolithic YTZP zirconia, and e.max CAD Crowns, (p < 0.05). 2. The highest static failure loads were shown by high strength monolithic (In-Ceram YZ) material, which were more resistant to cyclic loading compared to other veneered and monolithic systems. 3. The failure load of IPS e.max ceram group was significantly the lowest compared to all other groups. 4. The failure load data for IPS e.max CAD and Vita In-Ceram YZ structures revealed a significant difference in the effect of these structures on the failure loads (p < 0.05). Comparing structures, monolithic Vita In-Ceram YZ crowns showed the highest failure load. 5. There was a significant difference in failure mode among various veneered and monolithic systems (p 0.05).2020-10-24T00:00:00

Innovative Dental Technologies and Restorative Materials in Prosthodontics: New Perspectives and Future Developments

Digital technology is advancing rapidly in dentistry. Computers are making what were previously manual tasks easier, faster, cheaper and more predictable. Layered manufacturing processes can produce complex shapes at affordable prices with little or no waste. The challenge for the dental materials research community is to mach the new technology with materials that are suitable for use in dentistry. This can potentially take dental materials research in a totally different direction. The new generation of ceramic materials presents interesting options, both in terms of material selection and in terms of fabrication techniques. A closer understanding of the dynamics of the materials with respect to design of the restoration and the intended use is required to enable these restorations to perform productively

Chipping, failure load and fatigue resistance of anterior veneers manufactured with CAD/CAM technology

OBJECTIVES: To evaluate the marginal chipping of anterior veneers made with CAD/CAM by calculating the chipping factor, to evaluate the failure load of different veneering materials and thicknesses under static loading and cyclic loading. MATERIALS AND METHODS: An ivorine central incisor was prepared to receive a traditional veneer. Using epoxy resin, 120 replication dies were made of the prepared tooth. Four ceramic materials were used; IPS Empress CAD, IPS e.max CAD, VITA ENAMIC and Lava Ultimate. Veneers were milled using a Sirona InLab MCXL at three different thicknesses, 0.4mm, 0.7mm and 1.0mm, n=10 for each group. Veneers were inspected under the light microscope to calculate the chipping factor (CF). All veneers were cemented to their tooth replicas using Variolink Veneer resin cement. Five specimens/group were loaded under compression using an Instron universal testing machine at a rate of 0.5 mm/minute until fracture. Another five specimens were subjected to cyclic loading at 30% of the mean fracture load for 30,000 cycles at frequency rate of 1 Hz, and then were loaded under compression to fracture. Modes of failure were recorded after each test. RESULTS: IPS Empress CAD 0.4mm CF was higher than all other groups, and VITA ENAMIC and Lava Ultimate 1.0mm CF were the lowest. There was a significant difference in the failure load of the IPS Empress CAD and IPS e.max CAD groups under static loading but not in VITA EANMIC and Lava Ultimate groups. Cyclic fatigue had no significant effect on the failure load of different veneering materials and thicknesses. CONCLUSIONS: Chipping factor decreases as the material thickness increases and can be used as an indicator of material machinability. IPS e.max CAD at 1.0mm had the highest static failure load value when compared to other materials. Cyclic fatigue did not affect the failure load values within the groups tested.2019-09-26T00:00:00

Effect of the interface geometry on the structural integrity of the ceramic crown-tooth complex

The effect of the interface lute on the structural integrity of the tooth adhesively restored with an all-ceramic crown remains is an unknown parameter especially in relation to the interface geometry (thickness and uniformity). Traditionally, the structural integrity of a restored tooth system (tooth-lute-crown) is tested by laboratory based mechanical testing. However, a more sophisticated FEA computer modelling seems to provide a non-destructive way of understanding the structural integrity of the system, which may complement mechanical testing

AM Envelope:

This dissertation shows the potential of Additive Manufacturing (AM) for the development of building envelopes: AM will change the way of designing facades, how we engineer and produce them. To achieve today’s demands from those future envelopes, we have to find new solutions. New technologies offer one possible way to do so. They open new approaches in designing, producing and processing building construction and facades. Finding the one capable of having big impact is difficult – Additive Manufacturing is one possible answer. The term ‘AM Envelope’ (Additive Manufacturing Envelope) describes the transfer of this technology to the building envelope. Additive Fabrication is a building block that aids in developing the building envelope from a mere space enclosure to a dynamic building envelope. First beginnings of AM facade construction show up when dealing with relevant aspects like material consumption, mounting or part’s performance. From those starting points several parts of an existing post-and-beam façade system were optimized, aiming toward the implementation of AM into the production chain. Enhancements on all different levels of production were achieved: storing, producing, mounting and performance. AM offers the opportunity to manufacture facades ‘just in time’. It is no longer necessary to store or produce large numbers of parts in advance. Initial investment for tooling can be avoided, as design improvements can be realized within the dataset of the AM part. AM is based on ‘tool-less’ production, all parts can be further developed with every new generation. Producing tool-less also allows for new shapes and functional parts in small batch sizes – down to batch size one. The parts performance can be re-interpreted based on the demands within the system, not based on the limitations of conventional manufacturing. AM offers new ways of materializing the physical part around its&nbsp;function. It leads toward customized and enhanced performance. Advancements can for example be achieved in the semi-finished goods: more effective glueing of window frames can be supported by Snap-On fittings. Solving the most critical part of a free-form structure and allowing for a smart combination with the approved standards has a great potential, as well. Next to those product oriented approaches toward future envelopes, this thesis provides the basic knowledge about AM technologies and AM materials. The basic principle of AM opens a fascinating new world of engineering, no matter what applications can be found: to ‘design for function’ rather to ‘design for production’ turns our way of engineering of the last century upside down. A collection of AM applications therefore offers the outlook to our (built) future in combination with the acquired knowledge. AM will never replace established production processes but rather complement them where this seems practical. AM is not the proverbial Swiss-army knife that can resolve all of today’s façade issues! But it is a tool that might be able to close another link in the ‘file-to-factory chain’. AM allows us a better, more precise and safer realization of today’s predominantly free designs that are based on the algorithms of the available software. With such extraordinary building projects, the digital production of neuralgic system components will become reality in the near future – today, an AM Envelope is close at hand. Still, ‘printing’ entire buildings lies in the far future; for a long time human skill and craftsmanship will be needed on the construction site combined with high-tech tools to translate the designers’ visions into reality. AM Envelope is one possible result of this

AM Envelope

This dissertation shows the potential of Additive Manufacturing (AM) for the development of building envelopes: AM will change the way of designing facades, how we engineer and produce them. To achieve today’s demands from those future envelopes, we have to find new solutions. New technologies offer one possible way to do so. They open new approaches in designing, producing and processing building construction and facades. Finding the one capable of having big impact is difficult – Additive Manufacturing is one possible answer. The term ‘AM Envelope’ (Additive Manufacturing Envelope) describes the transfer of this technology to the building envelope. Additive Fabrication is a building block that aids in developing the building envelope from a mere space enclosure to a dynamic building envelope. First beginnings of AM facade construction show up when dealing with relevant aspects like material consumption, mounting or part’s performance. From those starting points several parts of an existing post-and-beam façade system were optimized, aiming toward the implementation of AM into the production chain. Enhancements on all different levels of production were achieved: storing, producing, mounting and performance. AM offers the opportunity to manufacture facades ‘just in time’. It is no longer necessary to store or produce large numbers of parts in advance. Initial investment for tooling can be avoided, as design improvements can be realized within the dataset of the AM part. AM is based on ‘tool-less’ production, all parts can be further developed with every new generation. Producing tool-less also allows for new shapes and functional parts in small batch sizes – down to batch size one. The parts performance can be re-interpreted based on the demands within the system, not based on the limitations of conventional manufacturing. AM offers new ways of materializing the physical part around its&nbsp;function. It leads toward customized and enhanced performance. Advancements can for example be achieved in the semi-finished goods: more effective glueing of window frames can be supported by Snap-On fittings. Solving the most critical part of a free-form structure and allowing for a smart combination with the approved standards has a great potential, as well. Next to those product oriented approaches toward future envelopes, this thesis provides the basic knowledge about AM technologies and AM materials. The basic principle of AM opens a fascinating new world of engineering, no matter what applications can be found: to ‘design for function’ rather to ‘design for production’ turns our way of engineering of the last century upside down. A collection of AM applications therefore offers the outlook to our (built) future in combination with the acquired knowledge. AM will never replace established production processes but rather complement them where this seems practical. AM is not the proverbial Swiss-army knife that can resolve all of today’s façade issues! But it is a tool that might be able to close another link in the ‘file-to-factory chain’. AM allows us a better, more precise and safer realization of today’s predominantly free designs that are based on the algorithms of the available software. With such extraordinary building projects, the digital production of neuralgic system components will become reality in the near future – today, an AM Envelope is close at hand. Still, ‘printing’ entire buildings lies in the far future; for a long time human skill and craftsmanship will be needed on the construction site combined with high-tech tools to translate the designers’ visions into reality. AM Envelope is one possible result of this

Numerical modelling of additive manufacturing process for stainless steel tension testing samples

Nowadays additive manufacturing (AM) technologies including 3D printing grow rapidly and they are expected to replace conventional subtractive manufacturing technologies to some extents. During a selective laser melting (SLM) process as one of popular AM technologies for metals, large amount of heats is required to melt metal powders, and this leads to distortions and/or shrinkages of additively manufactured parts. It is useful to predict the 3D printed parts to control unwanted distortions and shrinkages before their 3D printing. This study develops a two-phase numerical modelling and simulation process of AM process for 17-4PH stainless steel and it considers the importance of post-processing and the need for calibration to achieve a high-quality printing at the end. By using this proposed AM modelling and simulation process, optimal process parameters, material properties, and topology can be obtained to ensure a part 3D printed successfully