Skip to content

The Rise of Aerial Additive Manufacturing in Construction (2024-11)

A Review of Material Advancements

10.3389/fmats.2024.1458752

 Dams Barrie,  Chen Binling,  Kaya Yusuf,  Shepherd Paul,  Kovac Mirko,  Ball Richard
Journal Article - Frontiers in Materials, Vol. 11

Abstract

The construction industry has recently increased the adoption of additive manufacturing (AM, also known as 3D-printing) technologies. This review paper presents the state of the art of groundbased AM systems in construction, focusing comprehensively on developments in the material aspect towards using unmanned aerial vehicles (UAV), commonly referred to as 'drones'. AM itself is introduced, and an overview of the history of AM is provided. Key projects developing both ground-based cementitious and polymeric AM applications for construction purposes are reviewed along with material constituents, AM deposition methods and reinforcement techniques to mitigate against crack propagation. The review details a cutting-edge Aerial Additive Manufacturing (AAM) system developed to utilise untethered, self-powered UAV platforms extruding material during autonomous flight, which is designed to bring multi-agent aerial mobility to AM in the construction industry. An overview of the history of UAV development is presented, as well as the current use of UAV platforms combined with material deposition devices for construction and considerations for developing suitable materials and future research.

98 References

  1. Aghaee Kamran, Li Linfei, Roshan Alireza, Namakiaraghi Parsa (2024-08)
    Additive Manufacturing Evolution in Construction:
    From Individual Terrestrial to Collective, Aerial, and Extraterrestrial Applications
  2. Alghamdi Hussam, Nair Sooraj, Neithalath Narayanan (2019-02)
    Insights into Material-Design, Extrusion Rheology, and Properties of 3D Printable Alkali-Activated Fly-Ash-Based Binders
  3. Arunothayan Arun, Nematollahi Behzad, Ranade Ravi, Bong Shin et al. (2020-10)
    Development of 3D Printable Ultra-High-Performance Fiber-Reinforced Concrete for Digital Construction
  4. Asprone Domenico, Auricchio Ferdinando, Menna Costantino, Mercuri Valentina (2018-03)
    3D Printing of Reinforced Concrete Elements:
    Technology and Design Approach
  5. Baktheer Abedulgader, Claßen Martin (2024-07)
    A Review of Recent Trends and Challenges in Numerical Modeling of the Anisotropic Behavior of Hardened 3D Printed Concrete
  6. Bedarf Patrick, Dutto Alessandro, Zanini Michele, Dillenburger Benjamin (2021-08)
    Foam 3D Printing for Construction:
    A Review of Applications, Materials, and Processes
  7. Biswas Kaushik, Rose James, Eikevik Leif, Guerguis Maged et al. (2016-11)
    Additive Manufacturing Integrated Energy:
    Enabling Innovative Solutions for Buildings of the Future
  8. Bong Shin, Xia Ming, Nematollahi Behzad, Shi Caijun (2021-04)
    Ambient Temperature Cured ‘Just-Add-Water’ Geopolymer for 3D Concrete Printing Applications
  9. Bos Freek, Ahmed Zeeshan, Jutinov Evgeniy, Salet Theo (2017-11)
    Experimental Exploration of Metal-Cable as Reinforcement in 3D Printed Concrete
  10. Bos Freek, Ahmed Zeeshan, Wolfs Robert, Salet Theo (2017-06)
    3D Printing Concrete with Reinforcement
  11. Bos Freek, Bosco Emanuela, Salet Theo (2018-11)
    Ductility of 3D Printed Concrete Reinforced with Short Straight Steel-Fibers
  12. Bos Freek, Wolfs Robert, Ahmed Zeeshan, Salet Theo (2016-08)
    Additive Manufacturing of Concrete in Construction:
    Potentials and Challenges of 3D Concrete Printing
  13. Buswell Richard, Silva Wilson, Jones Scott, Dirrenberger Justin (2018-06)
    3D Printing Using Concrete-Extrusion:
    A Roadmap for Research
  14. Buswell Richard, Soar Rupert, Gibb Alistar, Thorpe Tony (2006-06)
    Freeform Construction:
    Mega-Scale Rapid Manufacturing for Construction
  15. 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
  16. Chen Yu, Figueiredo Stefan, Li Zhenming, Chang Ze et al. (2020-03)
    Improving Printability of Limestone-Calcined-Clay-Based Cementitious Materials by Using Viscosity-Modifying Admixture
  17. Chen Mingxu, Guo Xiangyang, Zheng Yan, Li Laibo et al. (2018-11)
    Effect of Tartaric Acid on the Printable, Rheological and Mechanical Properties of 3D Printing Sulphoaluminate Cement-Paste
  18. Chen Yu, He Shan, Zhang Yu, Wan Zhi et al. (2021-08)
    3D Printing of Calcined-Clay-Limestone-Based Cementitious Materials
  19. Chen Yu, Li Zhenming, Figueiredo Stefan, Çopuroğlu Oğuzhan et al. (2019-04)
    Limestone and Calcined-Clay-Based Sustainable Cementitious Materials for 3D Concrete Printing:
    A Fundamental Study of Extrudability and Early-Age Strength Development
  20. Chen Mingxu, Li Laibo, Wang Jiaao, Huang Yongbo et al. (2019-10)
    Rheological Parameters and Building Time of 3D Printing Sulphoaluminate-Cement-Paste Modified by Retarder and Diatomite
  21. Chen Mingxu, Liu Bo, Li Laibo, Cao Lidong et al. (2020-01)
    Rheological Parameters, Thixotropy and Creep of 3D Printed Calcium-Sulfoaluminate-Cement Composites Modified by Bentonite
  22. Chen Mingxu, Yang Lei, Zheng Yan, Huang Yongbo et al. (2020-04)
    Yield-Stress and Thixotropy-Control of 3D Printed Calcium-Sulfoaluminate Cement Composites with Metakaolin Related to Structural Build-Up
  23. Chougan Mehdi, Ghaffar Seyed, Jahanzat Mohammad, Albar Abdulrahman et al. (2020-04)
    The Influence of Nano-Additives in Strengthening Mechanical Performance of 3D Printed Multi-Binder Geopolymer Composites
  24. Chu Shaohua, Li Leo, Kwan Albert (2020-09)
    Development of Extrudable High-Strength Fiber-Reinforced Concrete Incorporating Nano-Calcium-Carbonate
  25. Cuevas Villalobos Karla, Chougan Mehdi, Martin Falk, Ghaffar Seyed et al. (2021-05)
    3D Printable Lightweight Cementitious Composites with Incorporated Waste-Glass-Aggregates and Expanded Microspheres:
    Rheological, Thermal and Mechanical Properties
  26. Dams Barrie, Chen Binling, Kaya Yusuf, Orr Lachlan et al. (2024-03)
    Fresh Properties and Autonomous Deposition of Pseudoplastic Cementitious Mortars for Aerial Additive Manufacturing
  27. Dams Barrie, Chen Binling, Shepherd Paul, Ball Richard (2023-01)
    Development of Cementitious Mortars for Aerial Additive Manufacturing
  28. Dams Barrie, Shepherd Paul, Ball Richard (2023-11)
    Development and Performance Evaluation of Fibrous Pseudoplastic Quaternary Cement Systems for Aerial Additive Manufacturing
  29. Delgado Camacho Daniel, Clayton Patricia, Brien William, Seepersad Carolyn et al. (2018-02)
    Applications of Additive Manufacturing in the Construction Industry:
    A Forward-Looking Review
  30. Ding Tao, Xiao Jianzhuang, Zou Shuai, Wang Yu (2020-06)
    Hardened Properties of Layered 3D Printed Concrete with Recycled Sand
  31. Ding Tao, Xiao Jianzhuang, Zou Shuai, Yu Jiangtao (2021-03)
    Flexural Properties of 3D Printed Fiber-Reinforced Concrete with Recycled Sand
  32. Ding Tao, Xiao Jianzhuang, Zou Shuai, Zhou Xinji (2020-08)
    Anisotropic Behavior in Bending of 3D Printed Concrete Reinforced with Fibers
  33. Dobrzanski James, Buswell Richard, Cavalaro Sergio, Kinnell Peter et al. (2021-09)
    Milling a Cement-Based 3D Printable Mortar in Its Green State Using a Ball-Nosed Cutter
  34. Ducoulombier Nicolas, Demont Léo, Chateau Camille, Bornert Michel et al. (2020-04)
    Additive Manufacturing of Anisotropic Concrete:
    A Flow-Based Pultrusion of Continuous Fibers in a Cementitious Matrix
  35. Figueiredo Stefan, Rodríguez Claudia, Ahmed Zeeshan, Bos Derk et al. (2019-03)
    An Approach to Develop Printable Strain-Hardening Cementitious Composites
  36. Ghaffar Seyed, Corker Jorge, Fan Mizi (2018-05)
    Additive Manufacturing Technology and Its Implementation in Construction as an Eco-Innovative Solution
  37. 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
  38. Hack Norman, Dörfler Kathrin, Walzer Alexander, Wangler Timothy et al. (2020-03)
    Structural Stay-in-Place Formwork for Robotic In-Situ Fabrication of Non-Standard Concrete Structures:
    A Real-Scale Architectural Demonstrator
  39. Hager Izabela, Golonka Anna, Putanowicz Roman (2016-08)
    3D Printing of Buildings and Building Components as the Future of Sustainable Construction?
  40. Heras Murica Daniel, Genedy Moneeb, Taha Mahmoud (2020-09)
    Examining the Significance of Infill-Printing-Pattern on the Anisotropy of 3D Printed Concrete
  41. Kaya Yusuf, Orr Lachlan, Kocer Basaran, Kovac Mirko (2023-12)
    Aerial Repair and Aerial Additive Manufacturing
  42. Kazemian Ali, Yuan Xiao, Cochran Evan, Khoshnevis Behrokh (2017-04)
    Cementitious Materials for Construction-Scale 3D Printing:
    Laboratory Testing of Fresh Printing Mixture
  43. Keating Steven, Leland Julian, Cai Levi, Oxman Neri (2017-04)
    Toward Site-Specific and Self-Sufficient Robotic Fabrication on Architectural-Scales
  44. Khajavi Siavash, Tetik Müge, Mohite Ashish, Peltokorpi Antti et al. (2021-04)
    Additive Manufacturing in the Construction Industry:
    The Comparative Competitiveness of 3D Concrete Printing
  45. Khalil Abdullah, Wang Xiangyu, Celik Kemal (2020-02)
    3D Printable Magnesium Oxide Concrete:
    Towards Sustainable Modern Architecture
  46. Khoshnevis Behrokh (2003-11)
    Automated Construction by Contour Crafting:
    Related Robotics and Information Technologies
  47. Kruger Jacques, Zeranka Stephan, Zijl Gideon (2019-07)
    An Ab-Inito Approach for Thixotropy Characterisation of Nano-Particle-Infused 3D Printable Concrete
  48. Le Thanh, Austin Simon, Lim Sungwoo, Buswell Richard et al. (2012-01)
    Mix-Design and Fresh Properties for High-Performance Printing Concrete
  49. Li Zhijian, Wang Li, Ma Guowei (2018-05)
    Method for the Enhancement of Buildability and Bending-Resistance of 3D Printable Tailing Mortar
  50. Li Leo, Xiao Bofeng, Fang Z., Xiong Z. et al. (2020-11)
    Feasibility of Glass-Basalt Fiber-Reinforced Seawater Coral Sand Mortar for 3D Printing
  51. Lim Sungwoo, Buswell Richard, Le Thanh, Austin Simon et al. (2011-07)
    Developments in Construction-Scale Additive Manufacturing Processes
  52. Lim Sungwoo, Buswell Richard, Valentine Philip, Piker Daniel et al. (2016-06)
    Modelling Curved-Layered Printing Paths for Fabricating Large-Scale Construction Components
  53. Lowke Dirk, Dini Enrico, Perrot Arnaud, Weger Daniel et al. (2018-07)
    Particle-Bed 3D Printing in Concrete Construction:
    Possibilities and Challenges
  54. Luhar Salmabanu, Suntharalingam Thadshajini, Navaratnam Satheeskumar, Luhar Ismail et al. (2020-12)
    Sustainable and Renewable Bio-Based Natural Fibers and Its Application for 3D Printed Concrete:
    A Review
  55. Ma Guowei, Salman Nazar, Wang Li, Wang Fang (2020-02)
    A Novel Additive Mortar Leveraging Internal Curing for Enhancing Inter-Layer Bonding of Cementitious Composite for 3D Printing
  56. Marchment Taylor, Sanjayan Jay (2019-10)
    Mesh Reinforcing Method for 3D Concrete Printing
  57. Masoud Laith, Hammoud Ahmad, Mortada Youssef, Masad Eyad (2024-06)
    Rheological, Mechanical, and Microscopic Properties of Polypropylene-Fiber-Reinforced Geopolymer Concrete for Additive Manufacturing
  58. Mechtcherine Viktor, Bos Freek, Perrot Arnaud, Silva Wilson et al. (2020-03)
    Extrusion-Based Additive Manufacturing with Cement-Based Materials:
    Production Steps, Processes, and Their Underlying Physics
  59. Mechtcherine Viktor, Michel Albert, Liebscher Marco, Schmeier Tobias (2020-06)
    Extrusion-Based Additive Manufacturing with Carbon Reinforced Concrete:
    Concept and Feasibility Study
  60. Mendoza Reales Oscar, Duda Pedro, Silva Emílio, Paiva Maria et al. (2019-06)
    Nanosilica-Particles as Structural Buildup Agents for 3D Printing with Portland Cement-Pastes
  61. Moeini Mohammad, Hosseinpoor Masoud, Yahia Ammar (2020-05)
    Effectiveness of the Rheometric Methods to Evaluate the Build-Up of Cementitious Mortars Used for 3D Printing
  62. Mohan Manu, Rahul Attupurathu, Schutter Geert, Tittelboom Kim (2021-01)
    Early-Age Hydration, Rheology and Pumping Characteristics of CSA Cement-Based 3D Printable Concrete
  63. Mohan Manu, Rahul Attupurathu, Tittelboom Kim, Schutter Geert (2020-10)
    Rheological and Pumping Behavior of 3D Printable Cementitious Materials with Varying Aggregate Content
  64. Munir Qaisar, Peltonen Riku, Kärki Timo (2021-08)
    Printing Parameter Requirements for 3D Printable Geopolymer Materials Prepared from Industrial Side Streams
  65. Muthukrishnan Shravan, Kua Harn, Yu Ling, Chung Jacky (2020-05)
    Fresh Properties of Cementitious Materials Containing Rice-Husk-Ash for Construction 3D Printing
  66. Natanzi Atteyeh, McNally Ciaran (2020-07)
    Characterising Concrete Mixes for 3D Printing
  67. Panda Biranchi, Lim Jian, Tan Ming (2019-02)
    Mechanical Properties and Deformation Behavior of Early-Age Concrete in the Context of Digital Construction
  68. Panda Biranchi, Paul Suvash, Lim Jian, Tay Yi et al. (2017-08)
    Additive Manufacturing of Geopolymer for Sustainable Built Environment
  69. Panda Biranchi, Ruan Shaoqin, Unluer Cise, Tan Ming (2018-11)
    Improving the 3D Printability of High-Volume Fly-Ash Mixtures via the Use of Nano-Attapulgite-Clay
  70. Panda Biranchi, Tan Ming (2018-03)
    Experimental Study on Mix Proportion and Fresh Properties of Fly-Ash-Based Geopolymer for 3D Concrete Printing
  71. Panda Biranchi, Tan Ming (2018-11)
    Rheological Behavior of High-Volume Fly-Ash Mixtures Containing Micro-Silica for Digital Construction Application
  72. Paolini Alexander, Kollmannsberger Stefan, Rank Ernst (2019-10)
    Additive Manufacturing in Construction:
    A Review on Processes, Applications, and Digital Planning Methods
  73. Paul Suvash, Tay Yi, Panda Biranchi, Tan Ming (2017-08)
    Fresh and Hardened Properties of 3D Printable Cementitious Materials for Building and Construction
  74. Pham Luong, Tran Jonathan, Sanjayan Jay (2020-04)
    Steel-Fiber-Reinforced 3D Printed Concrete:
    Influence of Fiber Sizes on Mechanical Performance
  75. Prihar Arjun, Garlock Maria, Najmeddine Aimane, Moini Mohamadreza (2024-01)
    Mechanical Performance of Sinusoidally Architected Concrete Enabled by Robotic Additive Manufacturing
  76. Putten Jolien, Azima M., Heede Philip, Mullem T. et al. (2020-06)
    Neutron-Radiography to Study the Water-Ingress via the Inter-Layer of 3D Printed Cementitious Materials for Continuous Layering
  77. Rahul Attupurathu, Santhanam Manu, Meena Hitesh, Ghani Zimam (2018-12)
    3D Printable Concrete:
    Mixture-Design and Test-Methods
  78. Rahul Attupurathu, Sharma Abhishek, Santhanam Manu (2020-01)
    A Desorptivity-Based Approach for the Assessment of Phase Separation During Extrusion of Cementitious Materials
  79. Rehman Atta, Kim Jung-Hoon (2021-07)
    3D Concrete Printing:
    A Systematic Review of Rheology, Mix Designs, Mechanical, Microstructural, and Durability Characteristics
  80. Sikora Paweł, Chougan Mehdi, Cuevas Villalobos Karla, Liebscher Marco et al. (2021-02)
    The Effects of Nano- and Micro-Sized Additives on 3D Printable Cementitious and Alkali-Activated Composites:
    A Review
  81. Song Hongwei, Li Xinle (2021-05)
    An Overview on the Rheology, Mechanical Properties, Durability, 3D Printing, and Microstructural Performance of Nanomaterials in Cementitious Composites
  82. Subrin Kévin, Bressac Thomas, Garnier Sébastien, Ambiehl Alexandre et al. (2018-09)
    Improvement of the Mobile Robot Location Dedicated for Habitable House Construction by 3D Printing
  83. Tay Yi, Panda Biranchi, Paul Suvash, Mohamed Nisar et al. (2017-05)
    3D Printing Trends in Building and Construction Industry:
    A Review
  84. Tay Yi, Ting Guan, Qian Ye, Panda Biranchi et al. (2018-07)
    Time-Gap-Effect on Bond Strength of 3D Printed Concrete
  85. Teizer Jochen, Blickle Alexander, King Tobias, Leitzbach Olaf et al. (2016-07)
    Large-Scale 3D Printing of Complex Geometric Shapes in Construction
  86. Thiel Charlotte, Hechtl Christian, Gehlen Christoph, Kränkel Thomas (2024-09)
    Sustainability Potential of Additive Manufactured Concrete Structures:
    Studies on the Life Cycle Assessment and Circularity of an Extruded Exterior Wall
  87. Ting Guan, Tay Yi, Tan Ming (2021-04)
    Experimental Measurement on the Effects of Recycled Glass-Cullets as Aggregates for Construction 3D Printing
  88. Voney Vera, Odaglia Pietro, Brumaud Coralie, Dillenburger Benjamin et al. (2021-02)
    From Casting to 3D Printing Geopolymers:
    A Proof of Concept
  89. Wangler Timothy, Flatt Robert (2018-09)
    Proceedings of the 1st RILEM International Conference on Concrete and Digital Fabrication:
    Correction
  90. Wangler Timothy, Lloret-Fritschi Ena, Reiter Lex, Hack Norman et al. (2016-10)
    Digital Concrete:
    Opportunities and Challenges
  91. Weng Yiwei, Ruan Shaoqin, Li Mingyang, Mo Liwu et al. (2019-06)
    Feasibility Study on Sustainable-Magnesium-Potassium-Phosphate Cement-Paste for 3D Printing
  92. Wolfs Robert, Bos Freek, Salet Theo (2018-02)
    Early-Age Mechanical Behaviour of 3D Printed Concrete:
    Numerical Modelling and Experimental Testing
  93. Xiao Jianzhuang, Zou Shuai, Yu Ying, Wang Yu et al. (2020-09)
    3D Recycled Mortar Printing:
    System-Development, Process-Design, Material-Properties and On-Site-Printing
  94. Zaid Osama, Ouni Mohamed (2024-04)
    Advancements in 3D Printing of Cementitious Materials:
    A Review of Mineral Additives, Properties, and Systematic Developments
  95. Zareiyan Babak, Khoshnevis Behrokh (2017-06)
    Inter-Layer Adhesion and Strength of Structures in Contour Crafting:
    Effects of Aggregate-Size, Extrusion-Rate, and Layer-Thickness
  96. Zareiyan Babak, Khoshnevis Behrokh (2018-04)
    _Effects of Mixture Ingredients on Inter-Layer Adhesion of Concrete in Contour Crafting
  97. Zhang Ketao, Chermprayong Pisak, Xiao Feng, Tzoumanikas Dimos et al. (2022-09)
    Aerial Additive Manufacturing with Multiple Autonomous Robots
  98. Zhang Xu, Li Mingyang, Lim Jian, Weng Yiwei et al. (2018-08)
    Large-Scale 3D Printing by a Team of Mobile Robots

1 Citations

  1. Ball Richard, Dams Barrie, Shepherd Paul, Chen Binling (2025-10)
    Exploring Aerial Additive Manufacturing with Cementitious Materials Using Autonomous Drones

BibTeX
@article{dams_chen_kaya_shep.2024.TRoAAMiC,
  author            = "Barrie Dams and Binling Chen and Yusuf Furkan Kaya and Paul Shepherd and Mirko Kovac and Richard J. Ball",
  title             = "The Rise of Aerial Additive Manufacturing in Construction: A Review of Material Advancements",
  doi               = "10.3389/fmats.2024.1458752",
  year              = "2024",
  journal           = "Frontiers in Materials",
  volume            = "11",
}
Formatted Citation

B. Dams, B. Chen, Y. F. Kaya, P. Shepherd, M. Kovac and R. J. Ball, “The Rise of Aerial Additive Manufacturing in Construction: A Review of Material Advancements”, Frontiers in Materials, vol. 11, 2024, doi: 10.3389/fmats.2024.1458752.

Dams, Barrie, Binling Chen, Yusuf Furkan Kaya, Paul Shepherd, Mirko Kovac, and Richard J. Ball. “The Rise of Aerial Additive Manufacturing in Construction: A Review of Material Advancements”. Frontiers in Materials 11 (2024). https://doi.org/10.3389/fmats.2024.1458752.