Optimization and intelligent manufacturing are of particular interest and important to improve the severe situation of excessive mass and uneven stress distribution for three-branch joints in treelike structures. In this work, the optimal shape of the three-branch joints under vertical load is studied by topology optimization method, and the complex topology optimization joint is manufactured using three-dimensional (3D) printing technology because it is difficult to produce by conventional manufacturing processes. First, the original model is optimized by using the OptiStruct solver in HyperWorks version 14.0 (64-bit) software, and the element density cloud map and element isosurface map of the model are obtained. Then, the static behaviors of the topology optimization model are compared with those of the hollow spherical joint model which is commonly used in engineering and those of the bionic joint model based on empirical design. Finally, the 3D printing technology is used to produce the topology optimization joint model, the hollow spherical joint model, and the bionic joint model. The process of production is characterized by converting the finite-element file of topology optimization joint into a standard template library (STL) file and then reading it into the slicing software to generate the 3D printing commands. The results show that the topological optimization joint has the most balanced stress distribution and the best static behaviors, which can provide reference for the design of joints in treelike structures. It is effective and feasible to use the combined technology of topology optimization and 3D printing to design and manufacture three-branch joints.

Additive Manufacturing (AM) technology has unique advantages in producing complex joints in architecturally exposed steel structures. This article focuses on the process of manufacturing and investigating the mechanical properties of a reduced scale model of a trifurcated joint using Selective Laser Melting (SLM) method and mechanical tests, respectively. The orthogonal test method was used to optimize the main AM process parameters. Then the trifurcated steel joint was printed using the optimal process parameters and treated by solid solution and aging treatment. To investigate the mechanical performance of the printed joint, an axial compression test and complimentary finite element analyses were carried out. Failure processes and failure mechanisms of the trifurcated steel joint were discussed in detail. The research results show that the preferred process parameters for printing 316L stainless steel powder are: scanning power 150 W, scanning speed 700 mm/s, and scanning pitch 0.09 mm. Using these AM parameters, trifurcated steel joints with good surface quality, geometrical accuracy and tensile strength are obtained after heat treatment. Our mechanical tests and Finite element analyses results indicate that the failure mechanism in the AM trifurcated joint are similar to those of cast steel joints. Based on these results, we conclude that the AM technology serves as a promising new way for the fabrication of joints with complex geometries.