Optimization of Glass Plate Structures with Additive Manufacturing

This thesis explores innovative approaches to improving the efficiency and sustainability of glass plate structures through additive manufacturing (AM) technologies. This research is located within the broader context of advancing sustainable building practices and optimizing the use of glass materials in construction, a material integral to modern architecture, but associated with high CO2 emissions due to its manufacturing processes.

This work addresses the critical need for reducing the environmental footprint of glass production by leveraging AM to selectively reinforce glass plate structures, thus minimizing material usage while maintaining or enhancing structural integrity. The thesis delves into the state of the art in AM technologies in the built environment (BE) and glass, assessing their potential applications of adopting such technologies in glass and facade engineering.

A significant contribution of this thesis is the detailed examination of the mechanical, optical, and economic requirements for glass in building structures, including facades, barriers, horizontal and interior glazing, alongside the legal framework governing their use. Through a comprehensive review of existing glass types and their applications, this thesis sets the stage for exploring how AM can revolutionize the design and construction of glass structures.

The core of the thesis is the experimental and theoretical optimization of glass plate structures. It presents a methodical approach to topology optimization, evaluating different algorithms, software tools and optimization methods. For this purpose, the physical properties, material model and fracture mechanical behavior of 3D-printed soda-lime glass were discussed, providing a foundation for the optimization process. By creating different optimized geometries for a defined load case, it demonstrates the potential to improve the structural efficiency of glass plates and shows potential material savings of up to 70%.

Mechanical tests on additively manufactured glass further underscore the practical aspects of this research, offering insights into the material properties and the performance of optimized glass structures. The thesis concludes with a critical assessment of the optimized plates, discussing their manufacturability, economic viability, ecological benefits, and compliance with safety standards. The thesis proposes avenues for future research and potential improvements in manufacturing processes, highlighting the role of mock-ups and visualizations for the entry of this technology into the BE. This thesis not only contributes to the academic discourse on sustainable glass constructions but also presents a viable path forward for the glass manufacturing industry to reduce its environmental impact.

The thesis’ findings demonstrate the feasibility of using AM to create optimized glass structures that meet the stringent requirements of modern construction while advancing the goals of aesthetics, sustainability and innovation in architectural design, highlighted through various visualizations.