Design methodology for the holistic optimization of truss structures with additively manufactured nodes under consideration of manufacturing and assembly restrictions

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Truss structures are an economical, stiff and effective lightweight design method, especially if complete utilization of the material with regard to strength and stiffness is desired. The use of fibre-reinforced materials for the struts is common practice but connecting elements between the struts - so-called nodes - are usually made of metals and are a challenge in terms of design, especially with optimized truss structures. In the present research project, a method for the holistic optimization of truss structures is being developed, implemented and evaluated, taking the special requirements of additive manufactured, fibre-reinforced nodes into account. The method accounts for the special requirements and freedom due to additive manufacturing of the nodes and the influence of anisotropic material and discrete component sizes on the overall design. Based on studies on the optimization of the overall structure and topology optimization of the connecting elements (nodes), the joints and the assembly of the structure is investigated in detail. Relevant parameters for assembly will be identified, same as the lightweight potential of the structure. The gained results are then used to develop a holistic optimization method for truss structures made of fibre-reinforced materials and additively manufactured nodes, taking manufacturing and assembly restrictions directly into account. In addition, methods for structural health monitoring of truss structures will be investigated in order to allow their use in failure-critical applications. Finally, the proposed nodes and a prototype of a truss structure are manufactured and experimentally validated with appropriate sensor technology in order to identify the limits of the new design approach and the upcoming research potential.