Introduction

This project was developed in collaboration with MX3D and ESA as a concept for a 3D-printed floor system. The floor structure was designed to meet efficiency, use, and construction constraints, the structure’s smooth web pattern design emerged from delineating stress map analysis and optimizing a continuous topology to reduce mass and make maximum use of 3D printing manufacturing methods.

It was printed using robotic ‘wire arc additive manufacturing’ out of 308LSi stainless steel and took about 246 hours to make, adding up to a total mass of approximately 395 kg and a maximum diameter of approximately 4.5 m once assembled.

The overall floor design is made out of six separate segments that were printed vertically before being welded together. The 3D-printed structure is supported by three columns and hosts a series of floor panels.

We looked at the manufacturing constraints and used our analysis to interpolate a web pattern that followed the angular limits of the 3D printing machines. The cross-section and thickness were also analyzed and differentiated to reduce the overall mass – with reduced thickness at the exterior/interior boundaries.