Parametric topology optimization design and analysis of additively manufactured joints in spatial grid structures.

• New computer-aided optimization design and additive manufacturing paradigm for steel joints in spatial grid structures is proposed. • Parametric topology optimization design method and numerical model for optimized joints are developed. • The structural performance of the optimized joints is investigated and compared with traditional joints. • A case study on double-layer spatial grid structure with hundreds of joints is presented to illustrate the applicability of the proposed paradigm. • Representative optimized joint is additively manufactured by selective laser melting using 316L stainless steel. This paper presents a complete computer-aided workflow for the parametric topology optimization (TO) design, numerical analysis and additive manufacturing (AM) of steel joints in spatial grid structures. A fully parametric TO design framework for steel joints in spatial grid structure was developed based on the Grasshopper platform. The joint models were parametrically established based on subdivision surface technology and further topology optimized through the bi-directional evolutionary structural optimization (BESO) algorithm with the support of cloud computing server. The structural performance of the optimized joints was thoroughly investigated via the parametric finite element analysis. Variables of loading conditions and TO parameters (target volume and filter radius) that affect the compliance, maximum displacement, maximum stress and stress distribution were taken into account. Analysis showed that the target volume governed the joint structural behaviour while the filter radius affected the geometric details of optimized joint. The practicability of proposed workflow was demonstrated through a parametric optimization design framework of a double-layer spatial grid structure with hundreds of steel joints. A typical optimized joint made of 316L stainless steel was additively manufactured using selective laser melting. This workflow is highly automatic and featured by high design flexibility and integration degree as well as good transplanted ability. [ABSTRACT FROM AUTHOR]