In this section
@article{Zuo:2026:10.1016/j.engstruct.2026.122148,
author = {Zuo, W and Chen, M-T and Zhao, O and Gardner, L},
doi = {10.1016/j.engstruct.2026.122148},
journal = {Engineering Structures},
title = {Parametric optimization-based design and testing of 3D printed stainless steel circular X-joints},
url = {http://dx.doi.org/10.1016/j.engstruct.2026.122148},
volume = {353},
year = {2026}
}
TY - JOUR
AB - The integration of topology optimization (TO) and metal 3D printing offers transformative opportunities for the design and fabrication of steel joints in spatial structures. This study develops a parametric joint TO-based design workflow, incorporating subdivision surface technology, the Bi-directional Evolutionary Structural Optimization (BESO) algorithm and advanced re-engineering techniques. Four X-joints for connecting circular tubes were optimized and then fabricated using Selective Laser Melting (SLM) with 316L austenitic stainless steel powder. To characterize the mechanical properties of the printed material, uniaxial tensile coupon tests were conducted in five loading orientations. The 3D printed steel optimized X-joints were tested under axial compression, with the deformations and the strains captured using 3D Digital Image Correlation. The structural response was assessed in terms of strain distribution, load-deformation behavior, joint strength and ductility, as well as failure mode. The results demonstrate that the 3D printed TO designed X-joints exhibit a more uniform distribution of stress, superior ductility and more efficient load transfer compared to conventional tubular joints. This excellent structural performance is due to the inherent high ductility of SLM-fabricated 316L stainless steel, the smooth geometric transitions achieved by means of subdivision surface technology, and the optimized material layout from BESO-based TO. The findings validate the feasibility of 3D printing TO designed joints for next-generation structural systems, with potential benefits in structural performance, fabrication efficiency and design flexibility.
AU - Zuo,W
AU - Chen,M-T
AU - Zhao,O
AU - Gardner,L
DO - 10.1016/j.engstruct.2026.122148
PY - 2026///
SN - 0141-0296
TI - Parametric optimization-based design and testing of 3D printed stainless steel circular X-joints
T2 - Engineering Structures
UR - http://dx.doi.org/10.1016/j.engstruct.2026.122148
UR - https://doi.org/10.1016/j.engstruct.2026.122148
VL - 353
ER -