Robotic AeroCrete A novel robotic spraying and surface treatment technology for the production of slender reinforced concrete elements

Taha, Nizar; Walzer, Alexander Nikolas; Ruangjun, Jetana

doi:10.5151/proceedings-ecaadesigradi2019_675

Cited by 21 publications

(21 citation statements)

References 3 publications

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“…A similar technique was developed by Gramazio Kohler Research at ETH Zurich using robotically sprayed concrete. In the AeroCrete project, a follow-up to the Mesh Mould research, a robot-assisted spraying process with fiber-reinforced concrete was investigated in order to produce thin shell constructions (see Figure 3b), [23]. In Figure 3c, differently from the previous projects, a concrete core was 3D printed first, and then a standard mat was pressed into the concrete and covered again with a layer of concrete [24].…”

Section: Use Of Continuous Fibers In Digital Fabrication and Additive Manufacturingmentioning

confidence: 99%

Development of a Robot-Based Multi-Directional Dynamic Fiber Winding Process for Additive Manufacturing Using Shotcrete 3D Printing

Hack

Bahar

Hühne

et al. 2021

Fibers

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The research described in this paper is dedicated to the use of continuous fibers as reinforcement for additive manufacturing, particularly using Shotcrete. Composites and in particular fiber reinforced polymers (FRP) are increasingly present in concrete reinforcement. Their corrosion resistance, high tensile strength, low weight, and high flexibility offer an interesting alternative to conventional steel reinforcement, especially with respect to their use in Concrete 3D Printing. This paper presents an initial development of a dynamic robot-based manufacturing process for FRP concrete reinforcement as an innovative way to increase shape freedom and efficiency in concrete construction. The focus here is on prefabricated fiber reinforcement, which is concreted in a subsequent additive process to produce load-bearing components. After the presentation of the fabrication concept for the integration of FRP reinforcement and the state of the art, a requirements analysis regarding the mechanical bonding behavior in concrete is carried out. This is followed by a description of the development of a dynamic fiber winding process and its integration into an automated production system for individualized fiber reinforcement. Next, initial tests for the automated application of concrete by means of Shotcrete 3D Printing are carried out. In addition, an outlook describes further technical development steps and provides an outline of advanced manufacturing concepts for additive concrete manufacturing with integrated fiber reinforcement.

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Section: Use Of Continuous Fibers In Digital Fabrication and Additive Manufacturingmentioning

confidence: 99%

Development of a Robot-Based Multi-Directional Dynamic Fiber Winding Process for Additive Manufacturing Using Shotcrete 3D Printing

Hack

Bahar

Hühne

et al. 2021

Fibers

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show abstract

“…This can either be a pragmatic toolpath design, for instance a space filling polyline to ensure the entire substrate is covered with print material. In this case, 25 a tensioned carbon fibre mesh is scanned using a Kinect RGBD scanner and a robotic toolpath for concrete spraying is generated according to the bounds of the geometry. It can also be an artistic toolpath design, such as using the topography of artistically shaped substrate as a driver for the design.…”

Section: Approaches That Do Not Assume An A-priori Geometric Definitionmentioning

confidence: 99%

Integrating real-time multi-resolution scanning and machine learning for Conformal Robotic 3D Printing in Architecture

Nicholas

Rossi

Williams

et al. 2020

International Journal of Architectural Computing

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Robotic 3D printing applications are rapidly growing in architecture, where they enable the introduction of new materials and bespoke geometries. However, current approaches remain limited to printing on top of a flat build bed. This limits robotic 3D printing’s impact as a sustainable technology: opportunities to customize or enhance existing elements, or to utilize complex material behaviour are missed. This paper addresses the potentials of conformal 3D printing and presents a novel and robust workflow for printing onto unknown and arbitrarily shaped 3D substrates. The workflow combines dual-resolution Robotic Scanning, Neural Network prediction and printing of PETG plastic. This integrated approach offers the advantage of responding directly to unknown geometries through automated performance design customization. This paper firstly contextualizes the work within the current state of the art of conformal printing. We then describe our methodology and the design experiment we have used to test it. We lastly describe the key findings, potentials and limitations of the work, as well as the next steps in this research.

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“…Recent advances in robotics in the area of architecture and civil engineering pushed the development of robotic spraying, where the goal is to automate the process as much as possible. Examples include spraying of plaster on flat walls (Jenny et al 2020) or concrete onto carbon fibre or reinforcement meshes (Taha et al 2019) (Fig. 1).…”

Section: Introductionmentioning

confidence: 99%

Depth-camera-based rebar detection and digital reconstruction for robotic concrete spraying

et al. 2021

Self Cite

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In this paper, we tackle the challenge of detection and accurate digital reconstruction of steel rebar meshes using a set of industrial depth cameras. A construction example under investigation in this paper is robotic concrete spraying, where material is sprayed onto double-curved single layered rebar meshes. Before the spraying process can start, the location and geometry of the rebar mesh needs to be accurately know. We present an automatic image-based processing approach of depth images for grid point extraction at an accuracy of a few mm. Furthermore, we propose a sequence of execution steps in a robotic setup, including the hand–eye calibration, which enables the direct georeferencing of multiple data sets acquired from various poses into a common coordinate system. With the proposed approach we are able to digitally reconstruct a mesh of an unknown geometry in under 10 min with an accuracy better than 5 mm. The digitally reconstructed mesh allows for computation of material needed for its construction, enabling sustainable use of concrete in digital fabrication. The accurately reconstructed digital mesh, generated based on the proposed approach in this paper, is the input for the following spraying step, allowing for generation of accurate spray trajectories.

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Robotic AeroCrete A novel robotic spraying and surface treatment technology for the production of slender reinforced concrete elements

Cited by 21 publications

References 3 publications

Development of a Robot-Based Multi-Directional Dynamic Fiber Winding Process for Additive Manufacturing Using Shotcrete 3D Printing

Development of a Robot-Based Multi-Directional Dynamic Fiber Winding Process for Additive Manufacturing Using Shotcrete 3D Printing

Integrating real-time multi-resolution scanning and machine learning for Conformal Robotic 3D Printing in Architecture

Depth-camera-based rebar detection and digital reconstruction for robotic concrete spraying

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