Yanan Guo

Abstract

The utilisation of bio-based materials has significantly increased in recent years, driven by a growing awareness of environmentally friendly alternatives in the construction industry. This study introduces innovative natural fibre pultruded profiles for load-bearing applications in structural systems. By employing pultrusion technology with flax fibres and customised plant-based matrix, linear and unidirectional biocomposite profiles were developed. These profiles were used in the creation of LightPRO Shell, an active-bending structure combining biocomposite profiles with a membrane outer skin, demonstrating their mechanical properties and suitability for such applications. The paper focuses on the geometrical and structural design development of the structure employing computational design tools for optimisation, ensuring design parameters and performance requirements were met. The final structure, a 10-m span doubly curved gridshell, features a continuous perimeter beam and consists of 44 profiles ranging from 6 to 12.5 m, showcasing the potential of natural fibre biocomposites as sustainable alternatives in construction.

Abstract

The linear design workflow for structural systems, involving a multitude of iterative loops and specialists, obstructs disruptive innovations. During design iterations, vast amounts of data in different reference systems, origins, and significance are generated. This data is often not directly comparable or is not collected at all, which implies a great unused potential for advancements in the process. In this paper, a novel workflow to process and analyze the data sets in a unified reference frame is proposed. From this, differently sophisticated iteration loops can be derived. The developed methods are presented within a case study using coreless filament winding as an exemplary fabrication process within an architectural context. This additive manufacturing process, using fiber-reinforced plastics, exhibits great potential for efficient structures when its intrinsic parameter variations can be minimized. The presented method aims to make data sets comparable by identifying the steps each data set needs to undergo (acquisition, pre-processing, mapping, post-processing, analysis, and evaluation). These processes are imperative to provide the means to find domain interrelations, which in the future can provide quantitative results that will help to inform the design process, making it more reliable, and allowing for the reduction of safety factors. The results of the case study demonstrate the data set processes, proving the necessity of these methods for the comprehensive inter-domain data comparison.

Abstract

Structural members made of fiber-reinforced polymers (FRP) attract increasing attention in the development of novel architectural systems that challenge the standard design methodologies. Cylindrical surfaces constitute one of the typical geometric sets obtained with the FRP component fabrication. This paper explores the influences of two geometric parameters on the buckling performance of elliptical cylinders: inverse slenderness (ratio of minimum diameter to height) and eccentricity (ratio of radii along semi-axes). The overall stiffness properties are defined using lamination parameters. This analysis method eliminates the dependency of optimal solutions on the initial assumptions regarding the laminate configuration, which needs to be explicitly described in multi-layer modeling. Finite element analyses are utilized to compute buckling loads of the cylinders under axial compression force and bi-axial bending moments. The optimal lamination parameters and buckling stresses are determined for various parameters, and the lamination parameters corresponding to the optimal and simple ±45° angle-ply design points are presented in the lamination parameter plane via Miki's diagram. The results reveal the level of performance that can be achieved by a specific geometry and provide guidelines for the optimal design of elliptical laminated cylinders against buckling.

Abstract

Coreless filament winding (CFW) is a novel fabrication technique that utilises fibre-polymer composite materials to efficiently produce filament wound structures in architecture while reducing manufacturing waste. Previous projects have been successfully built with glass and carbon fibre, proving their potential for lightweight construction systems. However, in order to move towards more sustainable architecture, it is crucial to consider replacing carbon fibre’s high environmental impact with other material systems, such as natural fibre. This paper evaluates several fibres, resin systems, and their required CFW fabrication adjustments towards designing and fabricating a bio-composite structure: the LivMatS Pavilion. The methods integrate structural design loops with material evaluation and characterisation, including small-scale and large-scale structural testing at progressive stages. The results demonstrate the interactive decision-making process that combines material characterisation with structural simulation feedback, leveraged to evaluate and optimise the structural design. The built pavilion is proof of the first successful coreless filament wound sustainable natural fibres design, and the developed methods and findings open up further research directions for future applications.

Abstract

In coreless filament winding, resin-impregnated fibre filaments are wound around anchor points without an additional mould. The final geometry of the produced part results from the interaction of fibres in space and is initially undetermined. Therefore, the success of large-scale coreless wound fibre composite structures for architectural applications relies on the reciprocal collaboration of simulation, fabrication, quality evaluation, and data integration domains. The correlation of data from those domains enables the optimization of the design towards ideal performance and material efficiency. This paper elaborates on a computational co-design framework to enable new modes of collaboration for coreless wound fibre–polymer composite structures. It introduces the use of a shared object model acting as a central data repository that facilitates interdisciplinary data exchange and the investigation of correlations between domains. The application of the developed computational co-design framework is demonstrated in a case study in which the data are successfully mapped, linked, and analysed across the different fields of expertise. The results showcase the framework’s potential to gain a deeper understanding of large-scale coreless wound filament structures and their fabrication and geometrical implications for design optimization.

Abstract

The applications of fiber-reinforced polymer (FRP) composites extend rapidly along with the development of new manufacturing techniques. However, due to the complexities introduced by the material and fabrication processes, the application of conventional structural design methods for construction members has been significantly challenging. This paper presents an alternative methodology to find optimum fiber layups for a given tube-shape geometry via a graphical optimization strategy based on structural performance requirements. The proposed technique employs simplified shell element models based on classical lamination theory (CLT) to avoid explicit fiber modeling in the FEA simulations. Lamination parameters are utilized to generate the reduced stiffness matrices for continuous multi-layer FRP lamination. The fiber layup of the component is retrieved from the optimal lamination parameters that maximize the structural performance. The case study results demonstrate that the developed method provides compact solutions, linking the structural design requirements with optimal fiber orientations and volumetric proportions. In addition, the determined solutions can be interpreted directly by the winding fabrication settings.