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Print-Cast Concrete (2020-07)

Additive Manufacturing for 3D Printing Mortar in Robotically Fabricated Green Sand Molds

10.1007/978-3-030-49916-7_75

Battaglia Christopher, Miller Martin,  Verian Kho
Contribution - Proceedings of the 2nd RILEM International Conference on Concrete and Digital Fabrication, pp. 757-767

Abstract

The research investigates architectural-scale concrete 3D printing in robotically fabricated recyclable molds for the fabrication of rapidly constructed, structurally optimized, architectural-scale concrete structures. The research of Print-Cast Concrete utilizes a three-dimensional extrusion path for deposition of material over a subtractive shaped sub-structure of CNC tooled compacted green sand. This process expedites the production of doubly curved concrete geometries by replacing traditional formwork casting or horizontal corbeling with spatial concrete arching deposited in relation to optimized structural loads. Creating robust non-zero Gaussian curvature in concrete, this method increases speed over typical pre-cast concrete fabrication practices, especially when producing mass customized unique elements. Through the casting component of this method, concrete 3D prints have greater resolution along the edge condition resulting in tighter assembly tolerances between multiple aggregated components. Addressing digital form finding and optimization, material behaviors, and novel utilization of robotic fabrication, this research work displays a series of key concepts within Print-Cast Concrete, advancing edge condition precision of extrusion-based 3DCP.

8 References

  1. Battaglia Christopher, Miller Martin, Zivkovic Sasa (2018-09)
    Sub-Additive 3D Printing of Optimized Double Curved Concrete Lattice Structures
  2. Bos Freek, Wolfs Robert, Ahmed Zeeshan, Salet Theo (2016-08)
    Additive Manufacturing of Concrete in Construction:
    Potentials and Challenges of 3D Concrete Printing
  3. Gosselin Clément, Duballet Romain, Roux Philippe, Gaudillière-Jami Nadja et al. (2016-03)
    Large-Scale 3D Printing of Ultra-High-Performance Concrete:
    A New Processing Route for Architects and Builders
  4. Hwang Dooil, Khoshnevis Behrokh (2004-09)
    Concrete Wall Fabrication by Contour Crafting
  5. Khoshnevis Behrokh (2003-11)
    Automated Construction by Contour Crafting:
    Related Robotics and Information Technologies
  6. Lim Sungwoo, Buswell Richard, Le Thanh, Austin Simon et al. (2011-07)
    Developments in Construction-Scale Additive Manufacturing Processes
  7. Verian Kho, Kowaleski Scott, Carli Matthew, Bright Randall et al. (2020-02)
    Properties of 3D Printing Mortar with the Development of a 3D Construction Printing Delivery System
  8. Zivkovic Sasa, Battaglia Christopher (2018-10)
    Rough-Pass-Extrusion-Tooling:
    CNC Post-Processing of 3D Printed Sub-Additive Concrete Lattice-Structures

4 Citations

  1. Wang Bolin, Yang Min, Liu Shilong, Liu Xianda et al. (2024-10)
    Research on Mechanical Properties of a 3D Concrete Printing Component-Optimized Path by Multi-Modal Analysis
  2. Madrid Javier, Ortega Guillermo, Gorostiza Carabaño Javier, Olsson Nils et al. (2023-02)
    3D Claying:
    3D Printing and Recycling Clay
  3. Buswell Richard, Xu Jie, Becker Daniel, Dobrzanski James et al. (2022-04)
    Geometric Quality Assurance for 3D Concrete Printing and Hybrid Construction Manufacturing Using a Standardised Test Part for Benchmarking Capability
  4. Verian Kho, Ashcroft Jarron, Ziemlaski Jim, Brodesser Tim et al. (2021-12)
    The Assessment of the Buildability and Inter-Layer Adhesion Strength of 3D Printed Mortar

BibTeX 
@inproceedings{batt_mill_veri.2020.PCC,
  author            = "Christopher A. Battaglia and Martin Fields Miller and Kho P. Verian",
  title             = "Print-Cast Concrete: Additive Manufacturing for 3D Printing Mortar in Robotically Fabricated Green Sand Molds",
  doi               = "10.1007/978-3-030-49916-7_75",
  year              = "2020",
  volume            = "28",
  pages             = "757--767",
  booktitle         = "Proceedings of the 2nd RILEM International Conference on Concrete and Digital Fabrication: Digital Concrete 2020",
  editor            = "Freek Paul Bos and Sandra Simaria de Oliveira Lucas and Robert Johannes Maria Wolfs and Theo A. M. Salet",
}
Formatted Citation

C. A. Battaglia, M. F. Miller and K. P. Verian, “Print-Cast Concrete: Additive Manufacturing for 3D Printing Mortar in Robotically Fabricated Green Sand Molds”, in Proceedings of the 2nd RILEM International Conference on Concrete and Digital Fabrication: Digital Concrete 2020, 2020, vol. 28, pp. 757–767. doi: 10.1007/978-3-030-49916-7_75.

Battaglia, Christopher A., Martin Fields Miller, and Kho P. Verian. “Print-Cast Concrete: Additive Manufacturing for 3D Printing Mortar in Robotically Fabricated Green Sand Molds”. In Proceedings of the 2nd RILEM International Conference on Concrete and Digital Fabrication: Digital Concrete 2020, edited by Freek Paul Bos, Sandra Simaria de Oliveira Lucas, Robert Johannes Maria Wolfs, and Theo A. M. Salet, 28:757–67, 2020. https://doi.org/10.1007/978-3-030-49916-7_75.