3DCP Printing - BI Final PDF

EMERGING CONSTRUCTION TECHNOLOGIES (SMaCT 3D Printing). Refilwe Lediga - B.Eng (Civil), M.Eng (Civil), PhD (Cand.) August , 2024  LECTURE OUTLINE Unit 1 - Background of 3D Printing Unit 2 - 3D Concrete Printing Unit 3 – 3D Concrete Printing Projects Unit 4 – 3DCP T...

EMERGING CONSTRUCTION TECHNOLOGIES (SMaCT 3D Printing). Refilwe Lediga - B.Eng (Civil), M.Eng (Civil), PhD (Cand.) August , 2024  LECTURE OUTLINE Unit 1 - Background of 3D Printing Unit 2 - 3D Concrete Printing Unit 3 – 3D Concrete Printing Projects Unit 4 – 3DCP Technologies Unit 5 – Project Implementation Unit 6 – Practical Challenges Unit 7 – Other Aspects to consider. 2 UNIT 1 – BACKGROUND OF 3D PRINTING 3  History of 3D Printing 3D printing was inverted in 1984 by Charles Hull. Through using a term STEREOLITHOGRAPHY (SLA), where designers prepare a 3D model which gets created layer by layer into a solid object. 4  History of 3D Printing Charles SLA was approved by 1986 and still one of the popular used 3D printing technology today. 3D printing also known as additive manufacturing is a process adopted to create 3D solid objects from a digital. Other popular automation technologies include: -Selective Laser Sintering (SLS) -Fused Deposition Modelling (FDM) -Direct Metal Deposition (DMD) First 3D printing on the market was established in 1992. 3D printing was used in the early days to print table top scale models. 5  3D Printing Process Stereolithography Slicing and Layer BIM or CAD Model File 3D Printer Combination (STL File) Housing Physical 3D Object Typology (Housing Typology) Start Finish 6 Milestones in 3D Printing 7 UNIT 2 – 3D CONCRETE PRINTING 8  Technologies used for 3DCP 3DCP is still in its infancy stages Very few companies have managed to successfully establish a manufacturing plant and run “Real-life” projects Printers are manufactured on a request basis, and takes about 3 - 6 months to assemble 3DCP Printers generally use commonly available building materials (cement and sand), with special proprietary material (additive) Opportunity to develop customised materials using local and waste materials 9 3D Printed Walling System Beginning of printing Middle slices of printing End of printing 10 On-Site Printing vs Factory Printing 11 Technology Uptake: International Perspective - 3DCP Number of 3DCP projects since 1997 (Buswell et al., 2018) 12 Technology Uptake: International Perspective - 3DCP Overview of 3D-printing applications (Ma et al. 2022) 13 Technology Uptake and Trens: International Perspective - 3DCP Mordor Intelligence, (2018) 14 Construction 3D Printing 15 Contour Crafting 16 1. Is 3DCP the future of Construction? 2. Is 3DCP faster than conventional Methods of Construction? 17 UNIT 3 - 3DCP PROJECTS 18  3DCP PROJECTS “World’s Biggest Building” Multi-Storey Buildings 19  3DCP PROJECTS “World’s Biggest Building” Bridge 20  3DCP PROJECTS “World’s Biggest Building” Wastewater chamber significantly 21  3DCP PROJECTS “World’s Biggest Building” Outdoor Furniture 22 Are there other practical applications of 3DCP you can think of ? 23 UNIT 4 - 3DCP TECHNOLOGIES 24 GANTRY SYSTEM Printing head/Nozzle Gantry Beam COBOD Gantry Column Printed Structure Foundation for Column 25  LARGE STRUCTURE Completed House 26 SIMPLIFIED GANTRY SYSTEM APIS COR 27 28 ROBOTIC ARM Put a full scale photo for CYBE here and label ???? SYSTEM APIS COR Printing head/Nozzle Robotic Arm Base 29 ROBOTIC ARM SYSTEM 30 CUSTOMIZED ARM SYSTEM APIS COR Printing head/Nozzle Extendable Arm Fixed Base 31 32 POLAR SYSTEM APIS COR 33 34 BOOM SYSTEM 35 36  SUMMARY (Edit) 1. Initial high capital cost (to be validated through the Life Cycle Cost). 2. Disruptive impact on skills required on-site (more high tech skills as opposed 3. to unskilled labour force). Complete value chain of housing delivery (from material acquisition to disposal) to be reviewed. Research in progress. 3.Huge potential to create more efficient and interesting designs as 3D printing can achieve shapes that conventional building techniques cannot (Typical “box match” houses). 4IR Transformative Technology in Construction 37 PART 2 38 UNIT 5 - PROJECT IMPLEMENTATION 39 ROBOTIC ARM SYSTEM 40 IMPLEMENTATION – ROBOTIC ARM SYSTEM Contractor: UJ SMACT Location: South Africa Printer Type: Robotic Arm System Project type: 40 SQM House (RDP House) 41 Our House Design Govt BNG 40 sqm house 42 Shape of house, corners stretched to test the technology Surveyor Points 43 Segmentation and Sequencing 44 3D Printed Walling System Beginning of printing Middle slices of printing End of printing 45 Foundation CS: 30 MPa 2 x Foundation 46 The 3D Printed Walling system Completed Superstructure 47  The Roofing System (Conventional Lightweight Steel) Job Creation Opportunities 48 Our House Design (Cont…) First 3D Printed House in South Africa Time to complete walls (Aggregated to an equivalent 8 hours). A wall takes approx. 45 minutes to complete Completed House 49 GANTRY SYSTEM 50 IMPLEMENTATION – GANTRY SYSTEMS Contractor : P2B Location: Angola Printer Type: Gantry System Project type: 200 SQM House 51 LABOUR 52 Pump PUMP 53 Nozzle NOZZLE 54 PRINTING 55 SITE SET UP 56 COMPLETED PROJECTS 57 Wastage Repurposing 58 UNIT 6 – PRACTICAL CHALLENGES 59 Wet Print 60 Wall To Wall 61 Gaps between walls Question? What is the best approach to fill the gaps? 62 Wall Overlap Question? How would you implement this overhang? 63 Wall Overhang 64 UNIT 7 – OTHER ASPECTS TO CONSIDER 65 Curing 66 Pump Feeding 67 Other complementary designs 68 Customised designs 69 Training Course Overview 70  Thank you Email: [email protected] Cell: 082 346 2417 71