Non-uniform truss modelling and energy consumption in adaptive space lattice manufacturing for steel structures

The present paper studies the energetic footprint of Adaptive Space Lattice Manufacturing (ASLM), a new metallic-based AM process joining solid rods through laser
spot welding. Associated energy costs are evaluated and compared with other metallic-based AM processes - machining, casting, powder-based AM and wire-based AM. Starting with measures of the energy consumption on site, a comprehensive study is performed across different units of measure (kWh/kg, kWh/rod, kWh/m3, kWh/I-beam). An energy breakdown is provided, including a material-process balance assessment through the integration of material embodied energy. Finally, the impact of design opportunities offered by ASLM is studied, evaluating various unit-cells lattice geometries across a sensitivity study. ASLM is found to achieve an 88,6-99,7% energy reduction compared to other AM technologies, and lattice configurations assessed feature 1:10 energy consumption differences.