Numerical Modelling of the World's First Metal 3D Printed Bridge

Abstract Recent disruptive technological advances, including wire arc additive manufacturing (WAAM) and the concept of digital twins, have the potential to fundamentally transform the way in which we design, build and manage structures. WAAM is a method of metal 3D printing that is well suited to the price‐sensitive construction industry and has been used to manufacture the MX3D bridge – the world's first metal 3D printed bridge. The intricate geometry, undulating surface finish and particular material properties rendered the bridge outside the scope of any existing structural design standards; hence, physical testing and advanced numerical modelling were carried out for its safety assessment. The key features of the finite element model of the bridge, and its validation against in‐situ structural tests, are described herein. Subsequent numerical studies undertaken to verify the structural performance of the bridge under various loading scenarios are presented, while the basis for the development of the smart digital twin of the bridge is also introduced. The presented research provides insight into the use of advanced computational simulations for the verification and ongoing assessment of structures produced using new methods of manufacture.