Toolpath-based design for 3D concrete printing of carbon-efficient architectural structures

Breseghello, Luca; Naboni, Roberto

doi:10.1016/j.addma.2022.102872

Cited by 31 publications

(15 citation statements)

References 21 publications

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“…SENS-ENV is an initial proof-of-concept which opens a new research territory for autonomous 3DCP, where robots will be able to gain increasing agency over multiple decision layers during the fabrication process and acquire a new design role. These capabilities could, in a short term, be employed for printing for and in harsh environments, and optimizing for structural (Breseghello and Naboni 2022) and environmental performance without a pre-planned optimised design. Our future undertakings will work towards the implementation of more articulated design and monitoring logic, integrating material features, e.g.…”

Section: Discussionmentioning

confidence: 99%

Environment-Aware 3D Concrete Printing through Robot-Vision

Naboni¹,

Breseghello²,

Sanin³

2022

eCAADe Proceedings

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In the 2020s, large scale 3D concrete printing (3DCP) is one of the most important areas of development for research and industry in construction automation. However, the available technology fails to adapt to the complexity of a real construction site and building process, oversimplifying design, production, and products to fit the current state of technology. We hypothesise that by equipping printing machinery with sensing devices and adaptive design algorithms we can radically expand the range of applications and effectiveness of 3DCP. In this paper we prove this concept through a full-scale design-tofabrication experiment, SENS-ENV, consisting of three main phases: (i) we equip and calibrate an existing robotic setup for 3DCP with a camera which collects geometric data; (ii) building upon the collected information, we use environment-aware generative design algorithms to conceive a toolpath design tailored for the specific environment with a quasi-real-time workflow; (iii) we successfully prove this approach with a number of fabrication test-elements printed on unknown environment configurations and by monitoring the fabrication process to apply printing corrections. The paper describes the implementation and the successful experiments in terms of technology setup, process development, and documenting the outcomes. SENS-ENV opens a new agenda for context-aware autonomous additive construction robots.

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Section: Discussionmentioning

confidence: 99%

Environment-Aware 3D Concrete Printing through Robot-Vision

Naboni¹,

Breseghello²,

Sanin³

2022

eCAADe Proceedings

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“…22 Another study, for example, used advanced print path design and varying robot speed to create parts with functionally graded density, specifically lightweight beam elements fabricated by concrete 3DP. 23 In general, print path strategies can be distinguished between planar and non-planar. For the former, Ding et al argue that infill path patterns can be categorized into six main types.…”

Section: Designing At Layer-scalementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Foamwork: Challenges and strategies in using mineral foam 3D printing for a lightweight composite concrete slab

Bedarf

Szabó

Scoccimarro³

et al. 2023

International Journal of Architectural Computing

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This paper presents an innovative design and fabrication workflow for a lightweight composite slab prototype that combines mineral foam 3D printing (F3DP) and concrete casting. Non-standardized concrete elements that are geometrically optimized for resource efficiency often result in complex shapes that are difficult to manufacture. This paper extends the research in earlier studies, showing that F3DP can address this challenge. F3DP is used to construct 24 stay-in-place formwork elements for a lightweight, resource-efficient ribbed concrete element with a 2 × 1.3 m footprint. This advancement highlights the improved robotic F3DP setup, computational design techniques for geometry and print path generation, and strategies to achieve near-net-shape fabrication. The resulting prototype shows how complex geometries that were previously cost-prohibitive can be produced efficiently. Discussing the findings, challenges, and future improvements offers useful perspectives and supports the development of this resourceful and sustainable construction technique.

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“…Recent innovations in digital fabrication of concrete elements related to formwork technologies such as fabric formwork [13,14], cable-nets [15], pin-bed moulds [16][17][18], and 3D printed and milled moulds [19] as well as advances in casting methods (mainly 3D printed concrete [20][21][22]) offers a potential solution to the manually intensive manufacturing process of concrete shells. In addition, the flexibility afforded by custom toolpath design such as stress-based 3D printing [23,24] allows for even greater material efficiency compared to what is possible using conventional construction methods. However, while 3D printing of concrete can accurately create shapes which lend themselves to extrusion (i.e., beams, columns, and walls), curved ribbed shells are not conducive to this method, as the print direction is not easily determined and the potentially weaker bond between layers can lead to delamination [20].…”

Section: Digital Fabrication Of Concrete Membersmentioning

confidence: 99%

Digital Fabrication of Ribbed Concrete Shells Using Automated Robotic Concrete Spraying

Nuh,

Oval,

Orr

et al. 2022

SSRN Journal

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Toolpath-based design for 3D concrete printing of carbon-efficient architectural structures

Cited by 31 publications

References 21 publications

Environment-Aware 3D Concrete Printing through Robot-Vision

Environment-Aware 3D Concrete Printing through Robot-Vision

Foamwork: Challenges and strategies in using mineral foam 3D printing for a lightweight composite concrete slab

Digital Fabrication of Ribbed Concrete Shells Using Automated Robotic Concrete Spraying

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