Case Study: TU Delft achieves ~32% weight reduction in a 3D‑printable canopy with Altair HyperWorks (OptiStruct)

Benefits of the Symbiosis of Topology Optimization and Additive Manufacturing in Architecture

TU Delft architectural student Bayu Prayudhi, supported by the Faculty of Architecture and the Built Environment at TU Delft, set out to test the potential of combining topology optimization with additive manufacturing for an architectural project by re‑designing the outdoor canopy at Baku International Airport. The challenge was to explore whether these methods could produce lighter, more efficient and aesthetically appealing structural elements suitable for real construction.

Using Altair’s HyperWorks suite—especially OptiStruct for topology optimization plus HyperMesh and HyperView for pre/post‑processing—Altair helped drive a redesign focused on 3D‑printable nodes and manufacturing constraints. The optimized design (validated via a scaled 3D‑printed mockup) estimated a ~32% weight reduction (from 34.9 t to 23.7 t, roughly 9 t saved), slightly increased canopy area, improved stiffness, simplified connection details, and the potential for reduced material, construction time and costs.

TU Delft