What is 3D Steel Engineering？

3D Steel Engineering (also called 3D structural steel design) is the process of digitally simulating and optimizing the design, manufacturing, construction and maintenance of steel structures using computer-aided design (CAD) and building information modeling (BIM) technology. In this design, the various components of the steel structure are accurately modeled in three-dimensional space for better analysis, optimization and coordination, ultimately achieving efficient construction and low-cost maintenance.

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Key features of 3D structural steel design

3D modeling

Steel structures are accurately modeled through 3D modeling tools such as Revit, Tekla Structures, AutoCAD, etc. Each component, including steel columns, steel beams, steel trusses, etc., is defined in 3D space, which can provide clearer visualization.

Design collaboration

3D design allows multiple design teams (such as structural designers, architects, electrical engineers, etc.) to work simultaneously in a shared 3D model. This collaborative work can reduce design errors, improve the accuracy of information, and effectively avoid conflicts in construction.

Accurate material calculation and optimization

In 3D Steel Engineering, the software can automatically calculate the required material quantity, size, weight and other parameters based on the design model, thereby optimizing the design plan, avoiding waste and reducing material costs.

Virtual construction and construction simulation

Through BIM technology, the construction process of the entire building can be simulated before construction, potential construction problems can be identified, and adjustments can be made in advance. This virtual construction can not only improve construction efficiency, but also reduce on-site changes and delays.

Automated manufacturing and processing

Based on the 3D design model, the components of the steel structure can be directly used for automated manufacturing equipment (such as CNC cutting machines, laser cutting machines, etc.) for precise processing. In this way, the information flow between design and production is more direct, reducing manual errors and processing time.

Component and node analysis

3D Steel Engineering can perform detailed analysis on each component and node of the structure to ensure that the steel structure has sufficient strength and stability in practical applications. At the same time, the software can automatically check for possible design defects, such as excessive stress or unreasonable connection methods.

Structural analysis and mechanical calculation

Using 3D modeling, detailed structural analysis of steel structures can be performed to calculate their stress, deformation, seismic resistance and other properties. Accurate mechanical analysis is performed through software (such as SAP, STAAD.Pro, etc.) to ensure structural safety.

Application areas of 3D Steel Engineering design

High-rise buildings and skyscrapers

3D structural steel design is often used in the steel structure design of high-rise buildings, especially those that require large spans and complex geometric shapes. Designers can simulate and optimize the building's load-bearing capacity, stability, and construction process in a virtual environment.

Industrial plants and warehouses

3D steel structure design is widely used in large-span industrial plants and warehouses. These buildings usually require open spaces and support structures, and 3D design can help accurately calculate the required amount of steel and structural support points.

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Gymnasiums and large public buildings

For large gymnasiums, exhibition centers and other buildings, the use of 3D steel structure design can effectively simulate large-span roofs, steel frame structures, etc., and optimize the support and seismic resistance of the structure.

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Aerospace and transportation facilities

In the design of transportation facilities such as aircraft hangars, train stations, and subway stations, steel structure design requires large structural bearing capacity and open space. 3D design can help accurately calculate and optimize the design.

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Army grant could advance high-grade steel 3D printing

Through the power of additive manufacturing, these materials could be widely used in defense-related applications, including personal armor and armored vehicles

By Erin Cassidy Hendrick

UNIVERSITY PARK, Pa. — Researchers in the Penn State College of Engineering received $434,000 from the United States Army to develop additive manufacturing, or 3D printing, techniques for high strength steels and alloys.

High strength and hardness steels are a class of materials that are well suited for and currently used in many defense-relevant applications, such as personal armor, armored vehicles, specialized facilities for blast and ballistic protection and marine ship hulls.

While high-grade steel is well suited for these uses, the material is difficult to manufacture traditionally.

“These steels exhibit much higher cracking sensitivities and lower overall weldability, which make them notoriously challenging to produce,” said Todd Palmer, professor of engineering science and mechanics and materials science and engineering.

Through this project, Palmer, the principal investigator of the project, and Amrita Basak, assistant professor of mechanical engineering and co-principal investigator, plan to expand the use of these materials in ways that will both save costs and increase utility by using additive manufacturing.

The laser-based directed energy deposition (L-DED) additive manufacturing process, which builds a component layer by layer and fuses them together with a laser, could allow engineers to design more intricate pieces. However, the properties of the steel and the printing process to create them need to be better understood and controlled.

“These materials are a completely new class for additive manufacturing,” Basak said. “What we find can help the research community pursue this further, and perhaps the Army will discover new ways to use these materials to further their mission.”

The researchers will specifically study a wire-fed manufacturing process, which introduces the source material compressed into a wire, as opposed to a powder. The researchers suggest this method could increase cost-effectiveness by producing fewer wasted materials.

The researchers explained that Penn State is uniquely positioned to take on this project.

“A real strength of Penn State is our vertical integration around additive manufacturing,” Palmer said. “We have experts on the experimental side and also on materials, numerical methods and machine learning. That’s what sets us apart: We can bring these people across disciplines together.”

Combined with the abilities of the faculty and students, the laboratories at Penn State — such as the Materials Research Institute, the Applied Research Laboratory, Center for Innovative Materials Processing Through Direct Digital Deposition and the Center for Innovative Sintered Products — provide the researchers with the ability to push the current boundary of additive manufacturing.

While a large part of the project will be using computer modeling to test and refine the parameters of the printing process, with these on-campus facilities, the team will not be limited to solely creating simulations. The researchers plan to manufacture large-scale components to provide impactful experimental data.

“In this project, we are exploring very large structures. If we didn’t have 3D printers large enough to create these, we couldn’t do much,” Basak said. “But we have many, and we will use them all to successfully complete this project.”