Sustainability in bridge design—investigation of the potential of topology optimization and additive manufacturing on a model scale

Bridge design represents a typical challenge in civil engineering. The high material usage in combination with the considerable construction effort makes their longevity a strongly desirable property. A mechanically efficient design contributes to optimum load distribution within the structure. Numerical topology optimization represents a valuable tool that can be applied for form finding of load-appropriate structural layouts within a predefined design-space. This study takes application of topology optimization to bridge design into focus. Different bridge types are designed using topology optimization considering self-weight based on a routine that was presented in a previous work. The bridge designs are examined in detail and compared to already existing bridges with regard to the requirements of modern structures. In order to demonstrate manufacturability of the designs, they are realized on a model scale using an additive manufacturing (am) technique in the powder bed. The knowledge gained from this small scale consideration is transferred to the context of civil engineering to highlight the potential of AM in realization of resource efficient construction.