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The advancements in additive manufacturing (AM) technology have allowed forthe production of geometrically complex parts with customizable designs. Thisversatility benefits large-scale space-frame structures, as the individualdesign of each structural node can be tailored to meet specific mechanical andother functional requirements. To this end, however, the design and analysis ofsuch space-frames with distinct structural nodes needs to be highly automated.A critical aspect in this context is automated integration of the local 3Dfeatures into the 1D large-scale models. In the present work, a two-scalemodeling approach is developed to improve the design and linear-elasticanalysis of space frames with complex additively manufactured nodes. Themechanical characteristics of the 3D nodes are numerically reduced through anautomated dimensional reduction process based on the Finite Cell Method (FCM)and substructuring. The reduced stiffness quantities are assembled in thelarge-scale 1D model which, in turn, enables efficient structural analysis. Theresponse of the 1D model is passed on to the local model, enabling fullyresolved 3D linear-elastic analysis. The proposed approach is numericallyverified on a simplified beam example. Furthermore, the workflow isdemonstrated on a tree canopy structure with additively manufactured nodes withbolted connections. The form of the large-scale structure is found based on theCombinatorial Equilibrium Modeling framework, and the different designs of thelocal structural nodes are based on generative exploration of the design space.It is demonstrated that the proposed methodology effectively automates thedesign and analysis of space-frame structures with complex, distinct structuralnodes.

Two-scale analysis and design of spaceframes with complex additive manufactured nodes