Methodology for biomimetic design of additively manufactured structural components
Publikationstyp
Doctoral Thesis
Date Issued
2026
Sprache
English
Author(s)
Advisor
Referee
Title Granting Institution
Technische Universität Hamburg
Place of Title Granting Institution
Hamburg
Examination Date
2025-10-29
Citation
Springer 978-3-032-27404-5: (2026)
ISBN
978-3-032-27405-2
978-3-032-27404-5
This thesis tackles a key challenge in lightweight design: developing detailed methods to create biomimetic designs based on topology optimization and produced by metal additive manufacturing. To address this, a novel five-step methodology was developed. Starting from an abstracted 3D model of cylindrical beams and spherical nodes derived via skeletonization, the approach applies finite element analysis to assess internal forces and moments. It then optimizes design parameters for two biomimetic and two conventional beam types across various load cases, selecting the lightest beam design for each case. Structural integrity is ensured through buckling analysis and re-dimensioning of beams. Nodes are adapted with lattice infill, maintaining powder removability while reducing weight. The final biomimetic components undergo validation via finite element analysis, with their mass compared against the original designs. Validated on three standard topology optimization problems, the method revealed localized high-stress regions and achieved significant weight reductions of 12.5% to 30.3%. Unlike previous approaches, it uniquely integrates internal force and moment evaluation for precise dimensioning of biomimetic beams, closing a gap in biomimetic design methodologies. This work advances the field of biomimetic lightweight design for industries such as aerospace and automotive, promoting more efficient and manufacturable components. The Author: Tim Röver (born 1992) earned his M.Sc. at Hamburg University of Technology (TUHH), where he conducted his PhD research. His work focuses on additive manufacturing, topology optimization, biomimetics, and numerical methods for mechanical and thermal component optimization. He held visiting researcher positions at Fraunhofer IAPT (Hamburg) and Mondragon University (Spain). At TUHH, Röver led a research group and currently serves as Head of Innovation in industry. He has co-authored over 16 peer-reviewed publications
Subjects
Engineering design
Light construction
Steel construction
Lightweight construction
Building materials
Industrial engineering
Production engineering.
DDC Class
620: Engineering