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3D Printing of Structural Pedestrian Bridge

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  • location_onMcCormick Place
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  • monetization_onPaid Upgrade
  • schoolNovice

With the development of large-scale additive manufacturing (AM) with filled polymers – including combined with continuous fiber – we open the door to create large, structural pedestrian bridges. Royal HaskoningDHV, CEAD Group and DSM have designed a fiber-reinforced polymer bridge made of glass fiber and Arnite® (PET), printed on a new award-winning, large-scale printer.  Based on a case study, this presentation will discuss the use of continuous fiber additive manufacturing (CFAM) and the use of 3D-printed polymers as a sustainable way to quickly create bridges with a low carbon footprint. We will discuss the benefits of a 3D-printed, fiber-reinforced polymer (FRP) bridge, which include durability (long lifetime expectancy, low life cycle costs), being lightweight (easy to relocate, minimal installation), sustainability (recyclable, no waste) and the use of digital technology (latest sensor techniques, data science). The possibilities for use of 3D-printed bridges include permanent structures, like cycle bridges or bridge deck replacements, as well as temporary structures for events, construction sites, emergencies or marine use.  We will present design optimization results, as well as feasibility study results, predictive modeling and simulation done prior to printing. We’ll also discuss printing of the bridge and prototype testing. We will share how the design and know-how of engineering consultancy Royal HaskoningDHV, the print technology from CEAD Group and the material solutions from DSM led to the creation of a new way of bridge design and construction, demonstrating how the manufacturing value chain can collaborate to move the 3D printing industry into the infrastructure market.

Learning Objectives:

  • Describe how three companies collaborated to create an innovative end result
  • Understand how additive manufacturing with filled polymers has opened the door for creation of large infrastructure, with potential to disrupt the bridge market and infrastructure segments
  • Greg Costantino
    New Business Development & Application Specialist
    DSM Additive Manufacturing
  • Maurice Kardas
    Business Development Manager
    Royal HaskoningDHV