Additive Manufacturing in Construction
AMC TRR 277

News

Research Summary Report of B05

Principles of Mobile Robotics for Additive Manufacturing in Construction [21.10.2022] Dielemans, Gido; Doctoral researcher, gido.dielemans@tum.de, Technical University of Munich, Department of Architecture, TT Professorship Digital Fabrication   Main goal This research examines the architectural implications of mobile robotics for AM in construction and develops methods for their implementation. The material deposition method of clay and concrete extrusion 3D printing is used to investigate mobile part-based AM strategies, that is, to produce large objects whose size exceeds the static workspace of the robot. By implementing advanced sensor and control solutions, autonomous localization and precise manipulation techniques for mobile AM are explored. In addition, this research aims to provide scalability to AM processes by examining the use of multiple robots to collaborate …

Research Summary Report of A08

Structural Timber by Individual Layer Fabrication (ILF) [14.11.2022] Buschmann, Birger; Doctoral researcher, birger.buschmann@tum.de, Talke, Daniel; Doctoral researcher, talke@tum.de Henke, Klaudius; Project leader, henke@tum.de Technical University of Munich, Chair of Timber Structures and Building Construction   Main goal The main goal of the project ‘A08 -Structural Timber by Individual Layer Fabrication (ILF)’ is to develop a process to additively manufacture large-scale, wood composite objects with a maximum content of wood material and strength values suited for applications in construction. In the course of the project multiple process variants and material combinations are explored. For this, the necessary machinery is developed in iterative steps and the mechanical properties of the resulting objects as well as the geometric capacity of the processes are …

Research Summary Report of A04

Integrated Additive Manufacturing Processes for Reinforced Shotcrete 3D Printing (SC3DP) Elements with Precise Surface Quality [11.11.2022] Freund, Niklas; doctoral researcher, n.freund@ibmb.tu-bs.de Lowke, Dirk; project leader, d.lowke@ibmb.tu-bs.de all: TU Braunschweig, Institute of Building Materials and Concrete Construction and Fire Safety (iBMB)   Main goal Project A04 investigates cooperative Additive Manufacturing (AM) processes based on Shotcrete 3D Printing (SC3DP) for the production of material-efficient, force-optimized, reinforced, load-bearing concrete components with precise surface quality and high geometric precision. The goal is to produce large-scale concrete elements using significantly lower amounts of reinforcement and concrete as compared to standard concrete construction principles. Summary In SC3DP applications, the precise control of rheological material properties represents a necessity. Here, data based rheological material models are required …

Research Summary Report of A05

Integration of Individualized Prefabricated Fibre Reinforcement in Additive Manufacturing with Concrete [02.11.2022] Gantner, Stefan; Scientific Researcher, stefan.gantner@tu-bs.de, TU Braunschweig, Institute of Structural Design (ITE)   Summary Cement-based additive manufacturing techniques need to be enhanced by the ability of integrating reinforcement, in order to fulfil requirements of construction. This project focuses on non-metallic continuous fibre reinforcement, which is not only corrosion resistant but also flexible in handling. Instead of bending and welding, glass or carbon fibre rovings can be processed by winding onto a support structure. Based on three fundamental AM-principles, namely material jetting and extrusion, as well as particle bed printing, a set of winding concepts for integrating reinforcement has been developed. Within a holistic framework all relevant aspects from …

Research Summary Report of A02

Particle-Bed 3D Printing by Selective Cement Paste Intrusion (SPI) – Particle Surface Functionalisation, Particle Synthesis and Integration of WAAM Reinforcement [28.10.2022] Riegger, Felix; Doctoral researcher; Felix.Riegger@iwb.tum.de Wimmer, Andreas; Head of the research group; Andreas.Wimmer@iwb.tum.de All: Technical University of Munich, Institute for Machine Tools and Industrial Management   Main goal The main goal of project A02 is the implementation of reinforcement with Wire and Arc Additive Manufacturing (WAAM) in concrete elements produced by Selective Paste Intrusion (SPI) by means of a simultaneously additive manufacturing process. The combination of SPI and WAAM is accompanied by obstacles that must be overcome to ensure the collaborated functionality. One major challenge occurs from the high energy input of WAAM (temperatures up to 1600 °C), which …

#11 Quarterly meeting at the AMC – quo vadis?

-english version below- Mitte Oktober trafen sich rund 80 Wissenschaftler:innen des Sonderforschungs-bereichs / Transregio 277 – Additive Manufacturing in Construction (AMC) im Rahmen Ihres 11. Quartalstreffens, um den aktuellen Projektstand der Teilprojekte zu präsentieren und zu diskutieren. Dabei lag der Fokus nicht nur auf – Was hat der AMC bis hierhin erreicht? sondern besonders auf – Was sind die nächsten Ziele des AMCs? Zentrale Aspekte des Treffens waren dabei besonders die etablierten und neu entwickelten Netzwerke zwischen den einzelnen Teilprojekten und die Planung von mehreren konkreten gemeinschaftlichen Anschauungsobjekten, sogenannten Demonstratoren. Die Erweiterung der bestehenden Netzwerke und die Entwicklung der Demonstratoren gehen hier Hand in Hand und verstärken die Zusammenarbeit der drei Focus Areas des AMCs. Die prozess- und materialorientieren Projekte …

Journalist of the computer magazine c´t visited the AMC

Journalist of the computer magazine c´t visited the AMC We are excited! The AMC – TRR 277 is in the latest issue of c’t. Europe’s largest IT- and tech- magazine from Heise Verlag (heise online) visited the AMC at the end of September and we talked about the research of the AMC, the special features of 3D-printing in construction and the potential it offers. Now the exciting article on the topic -Revolution in construction: 3D printing saves material and enables new forms- has been published in the current issue. Many thanks to Kathrin Dörfler, Harald Kloft, Dirk Lowke, Dr. Norman Hack and Janna Vollrath for your interviews and input. You can find the article here:   https://www.heise.de/select/ct/2022/23/2224916053682196709       …

Research Summary Report of C06

Integration of Additive Manufacturing in the Construction Process [06.10.2022] Placzek, Gerrit; Doctoral researcher, g.placzek@tu-braunschweig.de TU Braunschweig, IBB     Main goal The integration of additive manufacturing into construction requires an interdisciplinary approach. The different competences of the team – digital fabrication in architecture (Hack), geodesy and photogrammetry (Gerke) and construction management (Schwerdtner) – lead to research from diverse perspectives on the various scalar levels of construction to be viewed holistically: component, building and industry scale. Within Subproject C06, our goal is to create a continuous digital and lean-based process chain from design (using BIM method) to fabrication (using AM method). Based on process models, we investigate construction processes and how to change them into a construction industry 4.0. Summary The …

AdvanceAEC Autmn School 2022 – First Impressions

AdvanceAEC Autmn School 2022 – First Impressions At this year AdvanceAEC autumn school the AMC-Researchers Noor Khader, Gido Dielemans and Lukas Lachmayer hold a full-day workshop “revAMp – Additive Manufacturing in Construction: In situ Retrofitting Using AM with Mobile Robots”. In this workshop young scientists going to experimentally explore whether the deployment of mobile robots on building sites could be utilized for retrofitting, customized renovation, or repair by applying in situ extrusion 3D printing technology. The AMC is part of the AdvanceAEC network and the Autmn School is aimed at early career researchers, e.g. master students, PhD students and postdocs from the partner institutions of our network. This year’s AdvanceAEC Autumn School is hosted by IntCDC and is part of …

Wissenschaftliche/r Mitarbeiter/in (Doktorand/in, m/w/d) im Bereich der Fertigungsautomatisierung mit mobilen und kollaborativen Robotersystemen (EntgGr. 13 TV-L, 100 %)

We are looking for candidates who have demonstrated excellent achievements in research and teaching in an internationally recognized scientific environment, relative to the relevant career level (please see www.tum.de/en/faculty-recruiting-faq/ for further information). A university degree and an outstanding doctoral degree or equivalent scientific qualification, as well as pedagogical aptitude, are prerequisites. Substantial research experience abroad is expected.

Research Summary Report A07

Wire and Arc Additive Manufacturing (WAAM) of complex individualized steel components [30.09.2022] Müller, Johanna; doctoral researcher johanna.mueller@tu-braunschweig.de TU Braunschweig, Institute of Joining and Welding     Main goal The aim of TP A07 is the design, the manufacturing and the testing of complex individualized steel components by means of WAAM. That contains the fundamental investigation of design and the design process for WAAM components. For the manufacturing of steel components by WAAM, stable and reliable processes for basic geometries are qualified and based on that, case study demonstrators for the identification of manufacturing restraints are fabricated. Furthermore, a novel approach for material and component testing is developed to identify local material and component properties. Summary The aim of WG Hensel …

Research Summary Report C05

Jointing Principles for Combination of Concrete Elements Produced by Different Additive Manufacturing Processes [23.09.2022] Empelmann, Martin; Project Leader,            m.empelmann@ibmb.tu-bs.de Weigel, Hendrik; Doctoral Researcher,         h.weigel@ibmb.tu-bs.de TU Braunschweig, Institute of Building Materials, Concrete Construction and Fire Safety (iBMB), Division of Concrete Construction   Main goal The main goal of the C05 project is gaining fundamental knowledge for the design of dry joints in AM components. Therefore, the correlation between the execution and manufacturing on the load-bearing behaviour of dry joints will be investigated. Many different joint geometries are gathered, compared and evaluated by experimental testing and numerical methods. Summary The selected joint profiles from the so-called joint catalogue (see last RSR) are tested in terms of their compressive load-bearing behaviour. The …

Research Summary Report A06

Laser Powder-Bed Fusion (LPBF) of Steel Elements for Construction – Basics of Design and Mechanical Resilience [16.09.2022] Wenzler, David; Doctoral researcher; david.wenzler@tum.de Technical University of Munich, Institute for Machine Tools and Industrial Management Diller, Johannes; Doctoral researcher; johannes.diller@tum.de, Siebert, Dorina; Doctoral researcher; dorina.siebert@tum.de Technical University of Munich, Chair of Metal Structures The project A06 aims to explore and evaluate the factors influencing the manufacturing of safe and durable structural steel elements by Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M). Thereby, the PBF-LB/M process, the post-treatment, and the geometrical aspects in terms of microstructure and mechanical properties are investigated and correlations are determined. In the first funding period, the project is focused on analyzing small-scale specimens as well …

Research Summary Report C02

3D Structural Puzzle – Numerical Multi Scale Shape and Topology Optimisation Methods to Additively Manufacture Optimal Structures from Optimised Pieces [01.09.2022] Dr.-Ing. Reza Najian Asl (reza.najian-asl@tum.de); Prof. Dr.-Ing Kai-Uwe Bletzinger; TUM, Chair of Structural Analysis Current state of research Additive manufacturing in construction is a real enabler for the creation of optimal structures. It breaks the limitations of classical construction and provides the possibility of design and optimization for every feature and property of the structure, especially material and shape. To that end, a simulation-based  optimization tool has been developed at the Chair of Structural Analysis, TU Munich. The tool is implemented in the Kratos-Multiphysics open-source frame work and has the following state of the art features: (a) efficient and …

Research Summary Report A04

Integrated Additive Manufacturing Processes for Reinforced Shotcrete 3D Printing (SC3DP) Elements with Precise Surface Quality [26.08.2022] Dörrie, Robin: doctoral researcher, r.doerrie@tu-braunschweig.de, Technische Universität Braunschweig, Institut für Tragwerksentwurf Within this project, basic research on various Shotcrete 3D Printing (SC3DP) strategies, materials, tools and methods will be conducted with regard to enhanced material and process control, reinforcement integration, surface quality and automation. To that end, different reinforcement materials in combination with suitable reinforcement manufacturing and integration concepts will be investigated based on force-flow optimised reinforcement alignment. Besides, design strategies as well as material and process control will be investigated in detail. Furthermore, tools and strategies for precise control of the surface quality and geometric resolution of SC3DP elements are subject of research. …

AMC Summer School 2022

AMC Summer School 2022 – Summer, sun, lake and future The Collaborative Research Centre Transregio TRR 277 Additive Manufacturing in Construction (AMC) met at the end of July for an intensive research exchange at Lake Ammersee. For one week, the Haus der Bayerischen Landwirtschaft was home to 80 AMC scientists and their guests. Among them were students from the cooperating universities TU Braunschweig and TU München as well as the Venture Lab. The five days of the Summer School brought a breeze of fresh air to the AMC and motivated the researchers for the upcoming second phase of the overall project. This year’s AMC Summer School took a look back at the research highlights achieved so far as well as …

Research Summary Report A03

Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement [26.08.2022] Hechtl, Christian Maximilian, TP editor, m.hechtl@tum.de, TUM, Chair of Materials Science and Testing (cbm) Dr.-Ing. Matthäus, Carla, TP editor, c.matthaeus@tum.de, TUM, cbm Dr.-Ing. Kränkel, Thomas, PL, thomas.kraenkel@tum.de, TUM, cbm Prof. Dr.-Ing. Gehlen, Christoph, PL, gehlen@tum.de, TUM, cbm   The goal of A03 is to establish a concrete extrusion process using a near nozzle mixing approach to enable the change of material properties while printing (gradation). With this approach multifunctional components can be realized. For example, a component can simultaneously fulfill load-bearing and thermal insulation functions by locally changing the material properties. Current state of research The second iteration of the Gradation-ready Extrusion System …

Girlspower at the AMC Lab in Achering

#Girlspower at the AMC Lab -german version below- #Girlspower at the AMC Lab in Achering, TU München. Schoolgirls recently conducted research as part of the program “TUM Entdeckerinnen: MINT experience at university” themselves on 3D printing in construction. Next to several other helpers our colleague Maximilian Dahlenburg supervised the girls due to his sub-project “Extrusion of jet-mixed concrete – individually graded in bulk density and 3D fiber reinforcement” as part of the collaborative research project AMC – TRR 277 “Additive manufacturing in construction”. The girls learned about the process of basic research and were allowed to print an electronic random cube themselves. Munich, August 2022 About the AMC: The Collaborative Research Center Transregio TRR 277 Additive Manufacturing in Construction (AMC) …

Research Summary Report B04

Process Control and Adaptive Path Planning for Additive Manufacturing Processes Based on Industrial Robots with an Extended Degree of Freedom [19.08.2022] Lachmayer, Lukas; Doctoral researcher, lachmayer@match.uni-hannover.de Leibniz Universität Hannover, Institute of Assembly Technology (match) Function integration, topology optimization and automation increase productivity through the reduced workload, sustainability by less applied material and safety by decreasing manual labour. These benefits are condensed in most additive manufacturing processes, and thus, these are of significant interest to the construction industry. However, the time- and environment-dependent material properties of fresh concrete reduce the predictability of the material and thus often lead to component collapses during the manufacturing process. This project aims to achieve repeatability within concrete-based robot-guided additive manufacturing processes. Summary As expected and …

Research Summary Report C01

Bridging Scales – From Geometric Part Details to Construction Elements [16.08.2022] Kollmannsberger, Stefan; PL, stefan.kollmannsberger@tum.de, TUM, CMS Rank, Ernst; PL, ernst.rank@tum.de, TUM, Institute for Advanced Study Oztoprak, Oguz; WiMi, oguz.oztoprak@tum.de, TUM, CMS   Digital models for Additive Manufacturing (AM) must consider many different geometric scales. The scales range from micrometers up to tens of meters for metal- or concrete-based processes. The TP C01 aims to develop consistent geometric and computational descriptions for the relevant AM products on all of these scales. Based on the multiscale geometric models developed in earlier phases of this research project, we are now focusing on efficient simulation methods for AM products in construction with special emphasis on validation of the developed techniques. Summary The advances …