Automated Force-Sensitive Reinforcement for 3DCP (2024-07)¶

3D Concrete Printing (3DCP) is a promising technology in the construction industry, offering advancements in design flexibility, cost-effectiveness, and environmental sustainability. However, a major challenge in the widespread adoption of 3DCP for structural applications is the lack of a suitable in-process reinforcement method. Conventional reinforcement techniques are not directly applicable due to the distinct layered stacking process involved in 3DCP. To address this limitation, researchers have explored various reinforcement methods, but most of them only offer reinforcement along the printed layers’ direction and neglect interlayer reinforcement. Current interlayer reinforcement methods rely on labour-intensive pre/post-processes, which do not fully harness the true potential of 3DCP and its automation capabilities. To advance 3DCP technology, a reliable in-process vertical reinforcement method is crucial. The bar insertion method has emerged as a promising approach, allowing for the insertion of conventional reinforcing bars into freshly printed layers to create a continuous reinforcement. However, this technique faces challenges related to the voids forming around the bar, impacting bond strength and potential slippage. To overcome this, we propose the integration of force sensing and feedback control. By leveraging force sensing and feedback mechanisms, we can minimize disturbance during the insertion process and precisely control reinforcement placement. This approach enhances structural integrity and load-bearing capabilities by reducing void formation and improving bonding. Our study explores the potential of incorporating force sensing and feedback control in the bar insertion technique, drawing inspiration from the success of similar applications in additive manufacturing. Through our proposed approach, we envision a more efficient and effective 3DCP process, unlocking the technology's full advantages in terms of cost-effectiveness, speed, and design flexibility. By addressing the reinforcement challenge, our research contributes to the realization of 3DCP as a viable construction method capable of producing load-bearing structures.