Additive Manufacturing in Construction—Implementing Powder-Bed Fusion of Metals Using a Laser (PBF-LB/M) and Shape Optimization in the Construction Design Process †

In this study, the implementation of the PBF-LB/M process into the construction design and building process was investigated. To this purpose, a tensegrity-tower was designed, planned, and built. The nodes between the compression rods and the tension cables were manufactured by PBF-LB/M/AlSi10Mg. Four different nodes were designed and shape-optimized by vertex-morphing. In order to qualify the tensegrity nodes according to the German regulations, mechanical as well as microstructural evaluations were conducted. Tensile tests of a manufactured tensegrity node in a fully hinged setup were carried out. Additionally, fatigue testing was conducted. The tensegrity nodes were heat-treated (T6) and subsequently vibratory ground to reduce the surface roughness. The results indicate that it is feasible to integrate the PBF-LB/M process into the design and construction process. The tower is now a permanent and tangible exhibit in the Deutsches Museum in Munich.