Structural Performance Characteristics Research Articles

Structural and Mechanical Performance Characteristics of Construction Plasters with Different Material Compositions and Advanced Geopolymerization

Thermal performance-enhancing and weather-protective plasters for building elements are highly favoured in the construction industry. However, whilst substantial research has focused on the thermal performance characterisation of plasters, their mechanical properties still need to be explored. This study addresses exactly this gap by preparing plasters by TS EN 998-1 standard, with varying water/cement ratios of 0.8, 0.9, and 1. The plasters are formulated utilizing severe materials, including sand, perlite, and fibres. In addition, some plaster mixes are produced through geopolymerization by combining fly ash and blast furnace slag with a sodium hydroxide solution. The prepared plaster mixes underwent several mechanical and physical tests to determine the optimal configuration. These tests include flexural and compressive strengths, capillary water absorption values, adhesion strength, spreading diameter, and material weight loss under freeze-thaw conditions. The results indicate that diminishing the water/cement ratio enhances the flexural and compressive strengths of the plasters. Conversely, increasing the water/cement ratio improves the adhesion strength. The inclusion of polypropylene fibres reduces the adhesion strength, while perlitecontaining plasters exhibit lower freeze-thaw losses compared to other mixes. These findings offer practical insights for improving plaster formulations, addressing realworld challenges, including material availability, cost-effectiveness, and production - 145 - Structural and Mechanical Performance Characteristics of … Meltem Kaptan et al. scalability. The study underscores the potential of geopolymerization to advance sustainable construction practices whilst identifying limitations in implementation for broader industry adoption. Keywords: Freeze-thaw,

Design, Fabrication, and Performance Testing of PMMA Interference Screws Prepared by 3D Printing Methods

The Interference screws are one type of device that is often used in ACL reconstruction surgery. These devices are made of strong materials such as titanium or bioabsorbable materials. However, the use of PMMA (polymethyl methacrylate) as a material for the production of interference screws has not been widely explored. PMMA is commonly used in biomedical applications such as orthopedics and bone tissue engineering. Therefore, the aim of this study was to assess the structural integrity and performance characteristics of PMMA-based interference screws fabricated by utilizing three-dimensional (3D) printing techniques. The interference screw fabrication was carried out by adjusting the nozzle temperature, bed temperature, and print speed on the 3D printing machine to 240oC, 100oC, and 30 mm/s, respectively. The tests conducted in this study include torque, density, and fracture surface analysis. This study found that the density of the PMMA and commercial interference screws met the density requirements for cortical bone. However, the PMMA interference screw had a lower density than the commercial interference screw. The PMMA and commercial interference screws had densities (g/cm3) of 1.10 and 1.31, respectively. The mechanical properties of interference screws increase with increasing density. The PMMA interference screw achieved only 41% of the PFT (peak failure torque) exhibited by the commercial interference screw. In addition, the PMMA interference screw only meets the clamping criteria, while the commercial interference screw has met the good clamping criteria. The results of surface fracture analysis showed that the PMMA and commercial interference screws had ductile and brittle properties.

Synthesis and characterization of halloysite-cerium nanocomposite for removal of manganese

This study explores the use of a Halloysite composite to efficiently remove manganese from water through adsorption. We optimized experimental parameters, such as dosage (3 g/L), contact time, pH levels (ranging from 2 to 12), and initial Mn concentration (20 ppm), first in distilled water and then in polluted water. The main objective is to create an environmentally friendly material for practical manganese removal, especially important for at-risk populations like young individuals exposed to manganese. Using an oxidation-reduction approach, we synthesized a Halloysite-mediated nanocomposite for manganese removal through adsorption. The composite's crystallinity increased from 70.88 % to 77.4 % after manganese adsorption, indicating successful adsorption. At a transition temperature of 303 K, the composite showed an impressive 93 % manganese removal efficiency. We conducted comprehensive analyses using Scanning Electron Microscope (SEM), Energy Dispersive X-ray Spectroscopy (EDS), Transmission Electron Microscope (TEM), Fourier Transform Infrared Spectroscopy (FT-IR), X-ray diffraction (XRD), and UV–visible spectrophotometry to compare the composite's performance before and after adsorption. These results provide valuable insights into the structural changes and performance characteristics of the synthesized composite in manganese removal. Optimized experimental parameters and methodology lay the groundwork for further exploration of eco-friendly materials for water decontamination.

Using AFM to measure the elastic modulus of Diamond-Like Carbon thin films

In contemporary technological landscapes, a multitude of applications necessitate the fabrication of structures and mechanisms at exceptionally diminutive scales, prominently within the realm of Nano and Micro-Electro-Mechanical Systems (NEMS and MEMS). The comprehension of mechanical properties inherent in materials tailored for deployment in these applications assumes paramount significance. Consequently, an array of methodologies has been devised with the explicit purpose of delineating material properties at nano or micrometric scales. This report delves into select scholarly contributions aligned with this objective, and specifically, it explores a technique leveraging the capabilities of Atomic Force Microscopy (AFM) for the precise determination of the elastic modulus of Diamond-Like Carbon (DLC) films. The exploration of such methodologies is indispensable for advancing the understanding of material behavior at minute scales and facilitating the development of innovative technologies with enhanced structural integrity and performance characteristics.

NLFEA of the Behavior of Polypropylene-Fiber-Reinforced Concrete Slabs with Square Opening

The bending behavior of one-war reinforced concrete (RC) slabs with polypropylene fibers (PF) was examined in this study under the effect of different opening ratios using the nonlinear finite element analysis (NLFEA) method. The investigated parameters include the effect of different square opening ratios between 0 and 24% and PF volume percentages between 0 and 1% with 0.1% increments. The objectives of this study were fulfilled using 88 NLFEA models with different combinations of the studied parameters, including 11 control slabs without openings. The slab’s behavior was studied focusing on different structural performance characteristics, such as ductility, using energy-based and deflection-based approaches, stiffness (initial and yielding), cracking, and ultimate load strength. In addition, other structural performance parameters were considered, such as the crack opening, failure modes, and strain values, which were recorded for all specimens during the loading history. Moreover, the load-carrying capacity of the slabs was compared, looking at the NLFEA method’s results and the theoretical prediction results based on the sectional analysis method. However, it was observed that the inclusion of PFs of different percentages has a superior effect on the behavior of RC slabs with small openings (less than 2% opening ratio) compared to the acceptable improvements obtained for sabs with larger opening sizes. Consequently, PF could be utilized as a replacement for conventional steel rebars for RC slabs with small openings. In addition, increasing the PF percentage increases the resulting crack-opening value at failure due to the provided stabilization effect, in addition to increasing the system’s ability to sustain loads.

Analytical Modeling of Eco-Friendly Concrete Blocks from Construction and Demolition Waste using ANSYS

This research underscores the feasibility of repurposing C&D waste, particularly old concrete, for both new construction endeavors and revamping existing projects. This approach offers a dual advantage: preserving precious landfill space while curbing the extraction of raw materials for fresh construction initiatives. Focusing on the utilization of demolished waste as partial replacements for coarse aggregates sourced from C&D Waste Traders in Sirjala, Bengaluru, 10 mm sized recycled aggregates are employed.
 Recognizing the porous nature of crushed aggregates owing to residual slurry, a meticulous treatment process is adopted. This includes two-stage treatment involving abrasion to eliminate residual loose slurry, followed by immersion in a fly ash solution with a concentration ratio of 1:6. Subsequently, these treated aggregates, after the curing process, are amalgamated with a robust geopolymer precursor in a mix ratio of 1:3:6 to fabricate 400X200X150 mm blocks.
 To gauge the masonry behavior of these innovative concrete blocks, a battery of tests conforming to ASTM codes is meticulously conducted. These evaluations serve as a robust assessment of the structural integrity, durability, and performance characteristics of the blocks, providing critical insights into their potential for widespread adoption in construction practices. This comprehensive analysis contributes to the growing body of knowledge on sustainable construction materials and practices, advocating for a paradigm shift towards eco-friendly construction methodologies amidst the burgeoning challenges of waste management and resource scarcity.

Dynamic measurements to assess stress levels on buried hydraulic structures

ABSTRACT Old masonry structures have a very special nature that require periodical inspection and evaluation programs. The problem becomes more sophisticated when dealing with vital buried hydraulic structures under continuous functional operation while bearing additional loads from running public services such as railways. This could add extra challenges for determining their structural performance and engineering characteristics if conventional methods are used. Moreover, traditional methods are sometimes costly, time consuming, and can lead to some damage to the structure. The importance of the current research is therefore providing a rapid methodology for evaluating these structures to confirm their current ability to resist operating loads safely, especially when subjected to aging. In this study, the evaluation depends mainly on analyzing the vibration acceleration response of a structure under dynamic loads. Insight into system identification using formal modal analysis was also conducted. Simultaneously, calibrated numerical model was then adopted to predict the expected level of internal stresses. An old masonry irrigation intake buried culvert underneath the main railway lines was selected for examination. The structure was firstly plugged from both sides and emptied, site inspection as well as core sampling of construction materials were conducted. Vibration time history was recorded due to train passage with different speeds. The filed measurements along with mathematical model were used to estimate the level of stresses among the structure. The results showed the ability of the proposed method to evaluate structures in an easy and rapid fashion compared to traditional methods without stopping serviceability of the structure.

Structural design and performance characteristics of the fluidic sprinkler application technology for saving irrigation water: a review

The fluidic sprinkler was designed to have the prospect of a simple design, ease of construction, low energy consumption, and water saving. The present review focused on the fluidic sprinkler, compared the performance parameters of the fluidic sprinkler with the impact sprinkler, and highlighted the main challenges associated with the fluidic sprinkler. Even though the fluidic sprinkler compares quite well with the impact sprinkler, the review highlighted that the fluidic sprinkler appears to have more variability in application rate (0-1.5 mm/h) than the impact sprinkler (0-0.8 mm/h). The wetted radii were, on average, less than the impact sprinkler by 9.7, 9.3, 11.0, and 9.9% at 200, 250, 300, and 350 kPa operating pressures, respectively. Experiments on the fluidic sprinkler have mainly concentrated on the structural design of the fluidic component, water distribution profile, coefficient of uniformity, droplet size characterisation, and rotation uniformity, as well as the effect of different nozzle sizes on hydraulic performance under varying discharge and pressure conditions ranging from 100-500 kPa under indoor conditions. However, experimental studies on its performance in the field remain scanty. Statistical analysis of research papers published on the fluidic sprinkler indicates that less than 10% of the studies focused on the performance of the fluidic sprinkler on the field, and more than 90% on the design, structural and hydraulic performance under indoor conditions. Rotation stability of the fluidic sprinkler and testing with different sizes of the nozzle under low-pressure conditions on the field require further research to achieve energy and water saving through optimisation of the operating conditions.

Curing–dependent structural behavior of ultra-high-performance hybrid fiber-reinforced concrete beams

The application of ultra-high-performance fiber-reinforced concrete (UHP-FRC) is exceptionally versatile. However, a comprehensive understanding of UHP-FRC beam structural performance characteristics is lacking. The majority of research has concentrated on the behavior of structural members following standard water curing. This study investigated the impact of the curing regime on the structural performance of UHPC beams. The four different curing regimes used were standard, simulated hot arid weather, steam curing at various ages, and 5% sodium sulfate curing. Experimentally measured mechanical properties of UHP-FRC have been determined following ASTM guidelines, and the investigated beams have been tested under displacement-controlled four-point loading. Additionally, ACI 318 and FHWA-HIF codified formulas were employed in this study to predict the moment capacity of the tested beams. As a result of the various steam systems of varying ages, the load-carrying capacities of the beams were improved. By accelerating cement hydration, steam curing produces a stronger bond between fibers and the cementitious matrix, improving flexural strength. The control beam (under standard curing) showed a smaller maximum deflection, while all other beams showed similar deflection capacity. By accelerating the drying shrinkage, the beams under the 28-day standard with hot air curing were negatively impacted, with an average deflection value around 5% lower than control beams. The cured beams under simulated hot, arid conditions had the lowest flexural rigidity. A steam-cured beam had the highest moment-curvature performance, while a beam cured under simulated arid conditions had the lowest. Additionally, the ACI 318 design equation significantly underestimated beam maximum moments, while the FHWA approach marginally overestimated beam maximum moments with a predicted-to-tested average of 0.82.

Low-cost, ecofriendly, and large-scale synthesis of nanostructured Co1−xMnxFe2O4 microgranules with enhanced magnetic performance by chemical spray drying processing

We report, for the first time, the low-cost, eco-friendly, and large-scale synthesis of spray-drying production of Mn-substituted CoFe2O4 (Co1−xMnxFe2O4; x = 0.0–0.2; CMF) microgranules and their structural, morphological, and magnetic properties and performance characteristics in detail. The comprehensive study explored the intimate relationships between cation disorder or inversion degree due to Mn substitution in CoFe2O4 (CF) microgranules and corresponding changes in the structural and magnetic properties. Crystal structure and morphology studies indicate the formation of spherical shape, single cubic mixed inverse spinel structure of all the CMFO- microgranules with a size variation in the range of ⁓6.5–7.5 µm. Small angle X-ray scattering analyses indicate that the nanostructured CMF microgranules exhibit a virtually hard-sphere-like interaction. It is concluded that distortions are related to Co ions at octahedral locations due to Mn substitution in all materials. Raman spectroscopic studies, which corroborate with other structural studies, also reveal that replacing Co with Mn increases the degree of inversion in the cubic inverse spinel structure. Divalent (Co2+, Mn2+) and trivalent (Fe3+, Mn3+) cations are distributed differently across tetrahedral and octahedral sites. In addition to large-scale chemical synthesis, our results demonstrate the enhanced magnetic saturation from 82.27 to 86.18 emu/gm and 77.05–79.87 emu/gm for Co0.9Mn0.1Fe2O4 at 10 K and 300 K, respectively. In order for the proposed architectural design to serve as a crucial building block for a wide range of technological applications and be applicable to a large class of spinel ferrites, we present our attempt to draw the necessary fundamental scientific explanation from the trends in the local structural parameters and magnetic characteristics of CMF nanomaterials.

On-Site Manufacturing Method for Pre-Tension U-Type Pre-Stressed Concrete Girders and Analytical Performance Verification of Anchoring Blocks Used for Applying Tension Force

Development of U-type pre-stressed girders has been attempted to increase the length of I-type girders in South Korea. However, a length of 30 m or less is common because the self-weight, according to the post-tension method, is large. In this study, the pre-tension method was applied without limiting the post-tension method to induce a reduction in self-weight and in the materials used because of the decrease in the cross section. In addition, the authors proposed an application of an on-site pre-tensioning method using the internal reaction arm of a U-type girder. A pre-stressed concrete U-type girder bridge is composed of a concrete deck slab and a composite section. Structural performance characteristics, such as resistance and rigidity, were improved compared to those of the PSC I-type girders. Construction safety is also improved in the manufacturing and installation stages, and the elongation ratio is reduced because of the reduction in the weight of the girders. Therefore, it is possible to ensure the aesthetic landscape and economic efficiency of bridges. As a result, it is expected that efficient construction will be possible with high-quality factory-made and cast-in-place members. In this study, the pre-tension method is introduced in the field, and the analytical performance of the anchoring block used for tension is verified.

Mechanics of accelerated strain hardening in harmonic-structure materials

Harmonic-structure (HS) design is one of the most efficient in the family of architected gradient-structure materials recently attracting increasing attention in global material science community due to leading structural performance characteristics. This work studies in situ the mechanics of plastic deformation in HS materials on the example of commercially pure nickel (Ni) during uniaxial tensile loading. It reveals that strain partitioning between ultrafine and coarse grain fractions in HS Ni commences already at early stages of plastic deformation. Slow accumulation of strain in the ultrafine-grain regions leads to the slow consumption of ductility resource, while accelerated accumulation of strain in the coarse-grain regions leads to an accelerated strain hardening. These effects combined with evolving variations of strain tensor components have synergetic effect leading to the unique plastic behaviour and excellent structural performance of HS materials.

Experimental hysteretic behavior of high strength concrete columns confined by butt-welded closed composite stirrups

Six specimens of high strength concrete columns with butt-welded closed composite stirrups were tested under cyclic lateral loads, to study the structural performance (deformation) and hysteretic characteristics of the columns. The influences of the axial compression ratio and the volume-stirrup ratio were considered. According to the regression analysis of the test results, it was determined that the unloading stiffness and strength degradation rate under repeated loading conditions are mainly dependent on the two parameters of the “displacement ductility factor” and “axial compression ratio”. According to the test results, the skeleton curves were determined by the section layer and the statistical regression analysis methods. By considering the influence of axial compression ratio and the volume-stirrup ratio to the hysteretic characteristics of high strength concrete columns confined by butt-welded closed composite stirrups, the shear force-lateral displacement restoring force model was established. The results show that the axial compression ratio has a great influence on the strength degradation of the columns. As the axial compression ratio increases, the strength degradation of the columns occurs faster. On the other hand, the volume-stirrup ratio has a reverse effect on the strength degradation of the columns, with the increase of the volume-stirrup, the strength degradation of the column is observed gradually and slowly. The stiffness degradation of the columns increases as the axial compression ratio increases while the volume-stirrup ratio decreases.

The Role of Company Characteristics in the Quality of Financial Reporting in Indonesian

This study aimed to explain the role of company characteristics in shaping the quality of financial reporting in Indonesia, either simultaneously or partially, analyzed using Structural Equation Modeling. This study found that simultaneously structural characteristics, monitoring characteristics, and performance characteristics had a significant influence on the quality of financial reporting. While partially the characteristics of the structure and characteristics of monitoring had a significant influence on the quality of financial reporting. Meanwhile, performance characteristics did not influence the quality of financial reporting. It can be concluded that quality financial reporting can form good company characteristics and increase company performance, and can increase market response or market confidence in the current pandemic situation. The paper provides insight for the company to more concentrate on monitoring, structural, and performance to gain a good quality of financial reporting.

Engineering properties and lifecycle impacts of Pervious All-Road All-weather Multilayered pavement

Conversion of pervious natural ground into impermeable pavement systems has caused severe environmental impacts such as urban heat islands, increased infrastructure-related greenhouse gas (GHG) emissions and energy consumption, and runoff generation / flashfloods during rainfall events. These phenomena can be addressed with the use of pervious concrete pavement (PCP) systems, which have gained acceptance as sustainable alternatives to conventional materials. However, implementation of PCP technology is limited to low-volume roads, sidewalks, and parking lots attributed to low strength and the need for high quality control during construction compared to traditional pavements along with limited understanding on the end-of-life significance due to the green PCP product. Therefore, the major objective of this research was to develop a pavement system with superior structural and hydrological performance characteristics over traditional PCP, while also quantifying the energy consumed, amount of GHG produced, and costs associated with its design and construction. Thus, a Pervious All-Road All-weather Multilayered pavement (PARAMpave) was conceptualized and designed that comprised a 300 mm square paver block created with a 60 mm lower structural layer overlaid with a 30 mm water-draining surface wearing course pervious concrete layer. The major properties of PARAMpave products included porosity ranging from 17% to 24%, permeability varying from 0.77 cm/s to 1.33 cm/s, and flexural strength between 4.83 MPa and 6.13 MPa, indicating their improved structural and hydrological performance compared to traditional designs. Further, a cradle-to-gate lifecycle approach was utilized to perform a comparative evaluation between PARAMpave and Portland cement concrete (PCC) paver blocks. The PARAMpave products consumed lower energy (8.22% to 8.51%) and emitted lower GHGs (8.23% to 8.43%) compared to PCC blocks of similar dimensions. Additionally, PARAMpave blocks were about 10% cheaper and almost 10% lighter than a PCC paver block. The reduction in GHG emissions, energy consumption, and capital costs indicate that PARAMpave blocks are a sustainable class of roadway products. Also, the strength and permeability magnitudes of PARAMpave indicate that they have high potential for applications in different road classes and diversified weather conditions.

Upgrading seismic performance of underground frame structures based on potential failure modes

Most subway stations in China have been constructed recently and their seismic performance and potential failure modes are not well characterized. This paper is dedicated to identifying potential failure modes of underground frame structures through numerical simulations, and developing an optimized method for upgrading the seismic performance of deficient structures via controlling the potential failure modes. The dynamic response of an unequal-span subway station structure was calculated considering different ground motions with increasing peak horizontal acceleration, and the structural seismic performance characteristics were evaluated. Seismic performance evaluation indexes, including interlaminar deformation risk factor of columns and sidewalls and deflection risk factor of slabs, were established to identify the most critical structural component under strong earthquake excitations. The structure failure mechanism was analyzed, and consequently, the corresponding retrofitting scheme for upgrading its seismic performance was proposed. Finally, the structural responses before and after retrofit were calculated and compared to demonstrate the effectiveness of the retrofitting scheme. The results can improve the understanding of the failure modes of underground frame structures and provide references for their seismic design.

Energy‐efficient and sustainable composite facade constructions

Society currently undergoes a transformation process in understanding the environmental impact of its resource exploitation. The growing importance of resource‐efficiency and the reduction of the environmental impacts are being widely discussed and investigated. Therefore, the European Union (EU) countries have implemented energy efficiency regulations in all sectors, including the building sector, which is accountable for 40 % of energy consumption and 36 % of CO2 emissions within the EU. In modern facade constructions, the use of large‐scaled glass elements is inevitable, which has led to the investigation of potential optimization of structural performance, energy efficiency and ecological characteristics of the structural building components. The Department of Structural Design and Timber Engineering (ITI) at the Vienna University of Technology (TU Wien) developed several timber‐based composite systems, combining timber and wood concrete on the one hand, as well as timber and structural glass components on the other hand. Through various combination of the individual composite systems, certain advantages as well as the synergies resulting from the different combinations could be shown. Different types of combined timber, wood concrete and glass composite structures for facades are developed, assessed and compared to conventional facade structures. The comparison is carried out regarding the materialization on component level, as well as the overall construction level, whereby a scale‐independent assessment of the examined construction types could be reached. This assessment shall further be enabled by a broad‐spectrum computation, ranging from static and dynamic thermal simulations for annual heating and overheating periods up to various thereof resulting ecological impact calculations. In terms of ecological building design, the conceptual implementation of the building envelope plays an important role in the thermal comfort of the inner rooms, as well as the glare and reflection by the use of daylight. One advantage of large‐scale glass facades is the possibility to implement a high portion of solar entries into the total energy concept. The extremely versatile application possibilities allow different sectors of power generation, such as photovoltaic cells in the facade, thermal collectors for heat generation or algae panels, which generate biogas by photosynthesis process. The gained energy can further operate heating and cooling systems but also hot water supply.

Parametric Structural Topology Optimization of High-Rise Buildings Considering Wind and Gravity Loads

Topology optimization has recently been investigated as a technique for the conceptual design of efficient structures during the early stage of the design of buildings to tackle the design challenges. The use of this technique, which leads to optimum structures, mostly results in esthetic, lightweight, and best performance from the perspective of engineers or architects. However, the topology optimization results are not usually known for direct realization in practice, and the engineer and architect should be able to choose the best solution among numerous choices in close cooperation. This paper has focused on defining a parametric framework of continuous optimum design of lateral bracing systems for tall buildings considering wind and gravity loads. The bidirectional evolutionary structural optimization (BESO) method was employed, considering the main optimization parameter, loading scenarios, and constraints. In order to show the effectiveness of the suggested topology optimization framework for minimizing compliance (maximizing stiffness) and minimum consumption of materials in the design of lateral bracing systems, 2D and 3D systems have been discussed. According to the obtained results, this framework could employ topology optimization during the conceptual design to seek a new definition of the optimum layout of lateral bracing systems with high structural performance, elegant geometries, and other characteristics considered by architects and engineers.

Restoration of dynamic characteristics of RC T-beams exposed to fire using post fire curing technique

This paper presents experimental results of structural performance and dynamic characteristics of fire-damaged reinforced concrete (RC) T-beams subsequently repaired using the technique of post-fire curing. A total of six specimens were cast, two were unheated specimens, four specimens were exposed to 900 °C furnace temperature for 1 h. Two of the heated specimens were re-cured in water for 28 days. The dynamic characteristics such as frequency and damping were determined by exciting the beams using the free fall impact test. The beams were also subjected to load tests for strength and stiffness evaluation. Experimental results from load tests showed that T-beams lost approximately 40% strength and 33% stiffness when exposed to elevated temperatures. After post-fire curing, the beams regained almost 90% of their strength and stiffness. The loss of frequency in percent was found to be very similar to the stiffness values from load tests. The analytical modelling of the frequencies for undamaged, fire-damaged and repaired beams was carried out using lumped mass approach. The analytical and experimental results were found to be in good agreement. The change in dynamic characters due to fire damage is found to be an important factor, ignored in previous studies. All the beams exhibit failure in flexure during the third point loading test.

위상최적화를 적용한 검사장비용 진공 그리퍼의 경량 설계

Owing to recent advances in additive manufacturing technology, design for additive manufacturing (DfAM) has been used to overcome design limitations due to constraints in traditional manufacturing processes. In this study, we applied DfAM technology to design lightweight and consolidated vacuum grippers for inspection equipment. We proposed a consolidated design to reduce manufacturing time and costs, which previously encompassed assembling eleven components. Topology optimization was used to reduce part weight while maintaining structural rigidity and safety, and two optimization models were designed: two-piece and one-piece models. Based on these optimized geometries, the internal vacuum paths were designed in a curved shape to enhance adsorption characteristics. Numerical simulations were conducted to evaluate the structural performance and flow characteristics of the initial design and the two optimization models. The pressure drop of the one-piece model, which was the best design, was reduced to 1/8 of the initial design and the structural safety factor was predicted to be 6.37. This final design was then additively manufactured by a digital light processing type 3D printer and the weight of the resulting parts was reduced from 12.94 to 2.08 g. Experimental observation found that the additively manufactured vacuum gripper showed enhanced absorption performance compared to the initial design.