Arup claims 3D printing will produce more efficient steel components

Structural engineers at Arup claim new and radical designs for steel connections in construction can be achieved using 3D printing.

Also known as additive manufacturing, the approach means that manufacturers can create highly complex, individually designed pieces and print them directly in metal.

Arup said the process could also enhance the design and production process to the point that the weight and resulting cost of future construction materials could be reduced significantly.

“This is not only an exciting development for the construction sector, but many other industries as well,” said Arup Team Leader Salome Galjaard.

Steel connections could be designed 50% smaller and with a weight reduction of approximately 75%.

“On a construction project that means we could be looking at an overall weight reduction of the total structure of more than 40%. But the really exciting part is that this technique can potentially be applied to any industry that uses complex, high quality, metal products,” said Mr Galjaard.

The 3D technique uses lasers fired at metal alloy dust to fuse the compounds and, layer by layer, build up complex alloy shapes that can deliver far greater performance that traditional tube and flange joints.

The manufacturing process raises basic unit costs, but these can be offset by weight savings from far smaller, lighter elements in finished structures.