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<p>The increasing demand for large-scale, lightweight, and aesthetically customizable glass facades in modern architecture requires new approaches to enhance the mechanical performance of the used glass elements. This study presents the development and evaluation of a Direct Energy Deposition (DED) laser beam process for the additive manufacturing of reinforcement structures made of borosilicate and soda-lime-silicate glass. A self-designed experimental setup equipped with a CO₂ laser (λ = 10.6&#xa0;μm) and a temperature-controlled heated chamber was utilized to enable controlled deposition of glass rods onto heated glass substrates.</p><p>The process allows the direct fabrication of structural support structures on glass panes, achieving an in-plane accuracy of about Δs = 0.5&#xa0;mm. Residual stresses induced by the printing process were analyzed using photoelastic measurements. Mechanical performance was assessed via four-point bending tests supported by finite element simulations. Results show that the additively deposited support structures reduce stress under load at the substrate edge by approximately 75%, corresponding to a fourfold decrease compared to not reinforced samples. The stress reduction observed experimentally is in good agreement with numerical simulations.</p><p>The study shows that the additive manufacturing of glass with a DED laser beam processes can produce transparent, mechanically effective support structures, providing a novel method for localized strengthening and functional design integration in architectural glass applications.</p>

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Linear support structures made of glass using additive manufacturing

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年4月23日

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  • Franz Hesse,
  • Andreas Herrmann,
  • Jörg Hildebrand,
  • Jean Pierre Bergmann

摘要

The increasing demand for large-scale, lightweight, and aesthetically customizable glass facades in modern architecture requires new approaches to enhance the mechanical performance of the used glass elements. This study presents the development and evaluation of a Direct Energy Deposition (DED) laser beam process for the additive manufacturing of reinforcement structures made of borosilicate and soda-lime-silicate glass. A self-designed experimental setup equipped with a CO₂ laser (λ = 10.6 μm) and a temperature-controlled heated chamber was utilized to enable controlled deposition of glass rods onto heated glass substrates.

The process allows the direct fabrication of structural support structures on glass panes, achieving an in-plane accuracy of about Δs = 0.5 mm. Residual stresses induced by the printing process were analyzed using photoelastic measurements. Mechanical performance was assessed via four-point bending tests supported by finite element simulations. Results show that the additively deposited support structures reduce stress under load at the substrate edge by approximately 75%, corresponding to a fourfold decrease compared to not reinforced samples. The stress reduction observed experimentally is in good agreement with numerical simulations.

The study shows that the additive manufacturing of glass with a DED laser beam processes can produce transparent, mechanically effective support structures, providing a novel method for localized strengthening and functional design integration in architectural glass applications.