Module: 3D Digital Fabrication and Generative Design

Objectives

This module shows how digitalisation is transforming construction by combining large-scale 3D printing, digital and robotic manufacturing as well as computer-based generative design. Students gain a practical understanding of how digital manufacturing by large-scale 3D printing works, where it makes sense in construction, and how it can enable lighter, more sustainable, and customised structural components.
A central theme is the connection between digital manufacturing and lightweight design. Students learn how generative design, optimisation and basic machine learning (ML) methods can be used to explore design options efficiently and select solutions that balance structural performance, manufacturability, cost and environmental/sustainability impact.
After completing the module, students can:
(i) explain the fundamentals of large-scale steel 3D printing and robotic digital fabrication for construction automation and Industry 4.0.
(ii) identify typical 3D-printed-related issues (e.g., defects, distortion, residual stresses) and judge their structural relevance,
(iii) set up and interpret a generative design/optimisation problem for a lightweight structural component, and
(iv) understand how automation and AI/ML-supported workflows are shaping modern engineering practice.
This module is especially recommended for students interested in digital construction, construction automation, and sustainable lightweight design.

Topics

- Large-scale digital fabrication in construction: key processes in digital 3D printing, capabilities, and limits.
- Robotic welding-based manufacturing: fundamentals, melt pool behavior, defects, distortion, and residual stresses in steel manufacturing.
- Process–structure–property links: how 3D printing parameters affect microstructure and performance.
- Computer lab: introdicton to FEM in ABAQUS and programming basics in MATLAB.
- Testing lab: hands-on work with robotic 3D-printing systems in the lab.
- Techno-economics & sustainability: cost drivers, feasibility, and environmental impact of digital fabrication.
- Generative design: lightweight, resource-efficient designs optimized for 3D printing.
- Structural optimisation methods: classical to modern approaches, including multi-objective optimisation.
- Data-driven design: rapid design using simplified models and introductory AI/ML concepts.

Exam