A hemispherical research demonstration pavilion was presented to the public from April to October 2019. It was the first large-scale lightweight dome with a supporting roof structure primarily made of carbon- and glass-fiber-reinforced composites, fabricated by robotic coreless filament winding. We conducted monitoring to ascertain the sturdiness of the fiber composite material of the supporting structure over the course of 130 days. This paper presents the methods and results of on-site monitoring as well as laboratory inspections. The thermal behavior of the pavilion was characterized, the color change of the matrix was quantified, and the inner composition of the coreless wound structures was investigated. This validated the structural design and revealed that the surface temperatures of the carbon fibers do not exceed the guideline values of flat, black façades and that UV absorbers need to be improved for such applications.

In this study, the implementation of the PBF-LB/M process into the construction design and building process was investigated. To this purpose, a tensegrity-tower was designed, planned, and built. The nodes between the compression rods and the tension cables were manufactured by PBF-LB/M/AlSi10Mg. Four different nodes were designed and shape-optimized by vertex-morphing. In order to qualify the tensegrity nodes according to the German regulations, mechanical as well as microstructural evaluations were conducted. Tensile tests of a manufactured tensegrity node in a fully hinged setup were carried out. Additionally, fatigue testing was conducted. The tensegrity nodes were heat-treated (T6) and subsequently vibratory ground to reduce the surface roughness. The results indicate that it is feasible to integrate the PBF-LB/M process into the design and construction process. The tower is now a permanent and tangible exhibit in the Deutsches Museum in Munich.