A Review of Optimised Additively Manufactured Steel Connections for Modular Building Systems

This paper is presenting various types of innovative material technology that can be achieved by 3D printing and their potential to advance the connection design in modular building systems (MBSs). Connections can embrace flexibility, adaptability and resilience in the design of modular systems enabling dismantling, repair and reuse – towards faster transition to autonomous construction (e.g., with robotics). Rapid developments in additive manufacturing methods play a key role in the design such innovative mechanical systems.

Connections in modular buildings are the most critical parts of the system performance and integrity, but are currently receiving less attention compared with other structural elements (e.g., joists and studs). Optimised 3D printed connections can substantially improve the design of modular building systems with the ability to connect complex geometries and components that would be time and cost-prohibitive or even impossible to produce with traditional manufacturing methods. Therefore, this study reviews the latest connection designs of MBS units which can be replaced with 3D printed elements. In addition, advancements in additive manufacturing (AM) materials are included in this paper, exploring how AM can improve connection design in terms of both material properties and geometry.