Generative design and topology optimization research for single–layer aluminum alloy grid shell connections

The connection design of single–layer aluminum alloy grid shells traditionally relies on empirical strategies and is carefully tailored to specific construction requirements. However, confronting the intricacies inherent in the requirements of the contemporary era of intelligent construction poses rising challenges. This study aimed to enhance the connection design method for single–layer aluminum alloy grid shells on the basis of generative design (GD) and topology optimization (TO). First, mathematical models for GD and TO were outlined on the basis of the Audze–Eglais space–filling criterion and the solid isotropic material with penalization algorithm. Subsequently, GD and TO research were conducted on the single–layer aluminum alloy gird shell structure connection, with the glass skylight at Beijing Daxing International Airport used as a case study. Then, how various parameters, such as enhanced retention for different mass objectives, affect the diversity of outcomes in GD was explored. Ultimately, connections were created using 3D printing with polylactic acid, and the feasibility of using 3D printing technology to fabricate complex connections was assessed. Results showed that the GD surpassed TO in spatial exploration and model generation. The representative connection achieved through GD exhibited a 57 % decrease in mass and a 38 % reduction in maximum equivalent stress in comparison with the traditional plate–type connection. Additionally, 3D printing technology offered viable solutions for producing complex connections, boasting rapid and efficient manufacturing capabilities. • Advanced design method for single-layer aluminum alloy grid shell connections were proposed. • How various parameters affect the diversity of outcomes in generative design was explored. • Generative design provides enhanced spatial exploration and generation capabilities compared to topology optimization. • Advanced design combined with 3D printing for single-layer aluminum alloy grid shell connection was conducted.