Steel Gel casting is a novel method for manufacturing structural steel components with a hybrid approach that combines casting and 3D printed plastic molds. The project specifically targets the application of this method for bespoke connections for space structure and adds to the current knowledge by creating a new type of lightweight bespoke and integrative connection system.

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This project targets the development of a sustainable modus operandi for the construction of light- weight space structures with the use of an innovative AM material and an appropriate process chain for metal parts. Steel Gel casting is a novel method for fabricating stainless steel parts developed at the Fraunhofer IFAM. We identify the potential of this method for its use in the construction of spatial structures. It is method that is faster, cheaper and can be scaled up for architectural applications far more easily than state-of-the- art Direct Metal Laser Sintering.

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The process consists of:
1. the digital model, where a mold-making tool for gel casting is developed
2. the production of the discretized mold using off-the-shelf desktop 3D printers
3. casting of the steel suspension in specific conditions
4. dissolution of the mold
5. sintering of the metal components.

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This process ensures isotropic properties of the final components, and its production can be scaled up by mass sintering of the parts.