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Research Summary Report of A03
Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement [30.10.2024] Dr. Ing. Bos, Freek Project leader, freek.bos@tum.de Cheng, Shengbo Researcher, shengbo.cheng@tum.de Technical University of Munich, Chair of Concrete and Masonry Structures (Lehrstuhl für Massivbau) Extrusion-based 3D Concrete Printing (3DCP) is the most widely investigated technology for additive manufacturing (AM) in construction. Near-Nozzle Mixing (NNM) has been introduced in the 1st funding period of project A03 as a variant that can overcome several limitations of conventional 3DCP. Instead of mixing at a distance, NNM mixes the material constituents at the print head, thereby drastically reducing the transportation distance through hoses and the associated pumping pressure required. Thus, pumping-related …
Press release: Hands-on research with the 3D printer at the Long Night of Museums in Munich
Munich, October 2024 – The Collaborative Research Center Additive Manufacturing in Construction /TRR 277 AMC made a significant impact at the Long Night of Museums in Munich, held at the iconic Deutsches Museum. As part of the 25th anniversary of the city-wide cultural event, AMC brought cutting-edge construction technology to life through hands-on workshops and live demonstrations, sparking immense public interest. Making research tangible At the TUMlab, AMC researchers led by Anna Keune and the Ö project organised the ‘Clay Houses’ workshop, where participants explored the world of 3D design. Visitors created digital 3D models using TinkerCad, which were then transformed into physical clay objects. This interactive experience allowed nearly 200 attendees to engage with 3D printing in construction, blending …
Research Summary Report of C04
Integrating Digital Design and Additive Manufacturing through BIM-Based Decision Support and Digital Twin Methods [04.10.2024] Borrmann, André Project leader, andre.borrmann@tum.de Slepicka, Martin Researcher,martin.slepicka@tum.de All: Technical University of Munich, Chair of Computational Modeling and Simulation Additive Manufacturing (AM) is gaining more and more interest in the construction sector as it potentially offers many advantages, such as increased geometric freedom and productivity. However, these advantages come at a cost; additional effort is required in the data preparation for AM (a higher level of detail is necessary). Project C04 aims to simplify and streamline the necessary design and control processes and to interlink digital design (i.e. BIM) with automated fabrication. For this purpose, the Fabrication Information …
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 [27.09.2024] Hamilton, Leigh Duncan; Doctoral researcher; L.Hamilton@tu-braunschweig.de Zetzener, Harald; Leading researcher; H.Zetzener@tu-braunschweig.de Kwade, Arno; Project leader; A.Kwade@tu-braunschweig.de All: TU Braunschweig, Institute for Particle Technology To enable selective paste intrusion (SPI) for practical applications, the inclusion of reinforcement is mandatory. The focus of the first funding period was uniting SPI with wire arc additive manufacturing (WAAM) for reinforced concrete as well as functionalising and/or modifying particulate systems. During the first funding period, two main issues were identified: the need for ecological sustainable development for the combined process of SPI+WAAM and accelerated process velocities to improve the economic efficiency. Therefore, the …
Research Summary Report of A05
Integration of Individualized Prefabricated Fibre Reinforcement in Additive Manufacturing with Concrete [24.09.2024] Rothe, Tom; Doctoral researcher, t.rothe@tu-braunschweig.de, TU Braunschweig, Institute of Mechanics and Adaptronics (IMA) Hühne, Christian; Project Leader, Christian.Huehne@tu-braunschweig.de, TU Braunschweig, Institute of Mechanics and Adaptronics (IMA) The individual integration of fibre reinforcement into large additively manufactured concrete components allows new design freedom and reduces concrete consumption due to reduced concrete cover. Strategies for the integration of freely formable reinforcing strands for different AM processes are being developed in project A05. A Dynamic Winding Machine is used to prepare reinforcement strands. This machine is used to consolidate and impregnate a primary fibre strand and wind a secondary yarn around it as a surface structuring. Thus, these reinforcement strands …
Focus on Innovative Construction Technologies: Practical Workshops on Digital Fabrication
20 International PhD Students Visit Braunschweig At the beginning of September, TU Braunschweig became a hub for 20 young researchers attending a workshop in conjunction with the Digital Concrete 2024 conference. From September 1 to 3, these PhD students had the chance to experience cutting-edge research approaches and advanced infrastructure related to digital construction and fabrication processes firsthand. The workshops provided a hands-on introduction to Shotcrete 3D Printing and cyber-physical manufacturing technologies. Participants could dive deeper into the world of digital construction through technical presentations and practical sessions at the Digital Building Fabrication Laboratory (DBFL) and the Digital Construction Site (DCS). They followed each step of the construction process, from design to cyber-physical production, with the option to choose …
Research Summary Report of A06
Integrated Additive Manufacturing Processes for Reinforced Shotcrete 3D Printing (SC3DP) Elements with Precise Surface Quality [09.09.2024] Wenzler, David; doctoral researcher; david.wenzler@tum.de Technical University of Munich, Institute for Machine Tools and Industrial Management Blankenhagen, Jakob; doctoral researcher; jakob.blankenhagen@tum.de Technical University of Munich, Chair of Metal Structures Summary The project A06 aims to develop a methodology for producing safe and functional structural steel elements for construction using laser powder-bed fusion (LPBF). The LPBF steel Printdur HSA® will be qualified by using and transferring methodologies from the first funding period. The prediction of fatigue behaviour based on process monitoring data and machine learning will be explored. Lattice structures will be used to tailor the stiffness of the steel elements. These complex LPBF …
Digital Concrete 2024
400 scientists and one question: How will 3D-printing get to the construction site? At the Digital Concrete Conference 2024, international scientists met to discuss research findings, challenges and new technologies relating to 3D-printing in the construction industry and their requirements for materials and processes. Munich, September, 2024 – Digital Concrete 2024 concluded with great success, bringing together over 400 enthusiastic participants from around the globe for three exhilarating days of innovation, collaboration, and fun. From September 4-6, the 4th RILEM International Conference on Concrete and Digital Fabrication transformed Munichs Science Congress Center into a vibrant hub of creativity and cutting-edge technology. The event featured over 200 presentations across four dynamic parallel sessions, covering an impressive range of topics – from …
Research Summary Report of A04
Integrated Additive Manufacturing Processes for Reinforced Shotcrete 3D Printing (SC3DP) Elements with Precise Surface Quality [30.08.2024] David, Martin; Doctoral Researcher, m.david@tu-braunschweig.de TU Braunschweig, Institute for Machine Tools and Production Technology (IWF) Main Goal Project A04 aims to investigate cooperative Additive Manufacturing (AM) processes based on Shotcrete 3D Printing (SC3DP) for the production of material-efficient, force-optimised, reinforced, load-bearing concrete components with precise surface quality and geometrical precision. The goal is to produce large-scale concrete elements using significantly less reinforcement and concrete compared to standard concrete construction principles. Hereby, different robot guided end effectors are subject to research in a flexible and automated process chain. Currently, the following key points are researched: Development of end effectors for the processing of free-from …
Research Summary Report of A07
Wire and Arc Additive Manufacturing (WAAM) of Complex Individualized Steel Components [23.08.2024] Müggenburg, Marc; Doctoral Researcher, marc.mueggenburg@tu-braunschweig.de Unglaub, Julian; Project Leader,j.unglaub@tu-braunschweig.de Institute of Steel Structures Technische Universität Braunschweig Main Goal A07 focuses on understanding the interaction between DED-Arc (alias WAAM) components and existing structures, developing load-specific strengthening solutions and designing welding strategies. The specific challenges of adaptive design and adaptive manufacturing of large-scale high-strength steel DED-Arc components will be addressed and a digital twin including data from the design and manufacturing process, surface geometry and component performance will be elaborated. Physical and virtual component tests will be carried out to gain a comprehensive knowledge on buckling behavior, the effect of imperfections, load-carrying capacity and ductility. Overall, the project …
AMC Youth Spotlight: Lia’s Internship Experience with Project Ö
At AMC, we are committed to nurturing the next generation of innovators and thought leaders. One of the shining examples of this commitment is Lia, a talented intern who recently completed her internship as part of our Project Ö initiative. During her time with us, Lia delved into the fascinating intersection of design, technology, and sustainability. Her primary focus was on the use of advanced digital tools to create 3D models, which were then realized through the innovative process of robotic clay printing. Utilizing iPads, Lia explored the potential of these cutting-edge techniques to shape a future where digital fabrication plays a key role in sustainable construction. Lia’s work was not merely about mastering the technical aspects of 3D printing; …
Research Summary Report of B04
Process Control and Adaptive Path Planning for Additive Manufacturing Processes Based on Industrial Robots with an Extended Degree of Freedom [09.08.2024] Ekanayaka, Virama; Doctoral researcher, v.ekanayaka@tu-braunschweig.de, TU Braunschweig, Institute of Machine Tools and Production Technology (IWF) Hürkamp, André; Project Leader, a.huerkamp@tu-braunschweig.de, TU Braunschweig, Institute of Machine Tools and Production Technology (IWF) The integration of robot-guided additive manufacturing in the construction industry increases the degree of automation and can thus lead to an increased productivity and increased component quality. In shotcrete 3D printing (SC3DP), reproducible manufacturing results and ensuring component quality are major challenges, as the properties of shotcrete depend on many different parameters (e.g. temperature, pressure, water-cement ratio, hardening accelerator). The goal of this research project is to develop …
Research Summary Report of A03
Extrusion of Near-Nozzle Mixed Concrete – Individually Graded in Density and in Rate of 3D Fibre Reinforcement [03.07.2024] M.Sc. Dahlenburg, Maximilian; maximilian.dahleburg@tum.de Prof. Dr.-Ing. Fottner, Johannes; j.fottner@tum.de TUM, Chair of Materials Handling, Material Flow, Logistics Main Goal In the first funding period the feasibility of multiple Near-Nozzle-Mixing approaches (NNM) were studied by iteratively developing a working prototype: the Gradation-Ready-Extrusion-System (GRES). The latest process mixes paste and aggregates at the end-effector, eliminating the challenging long pumping distances of State-of-the-art Extrusion based 3D Concrete Printing systems (E3DCP). This solves the process- and material development conflict of having a highly workable material for pumping and the contrasting need for a highly buildable material after strand deposition. Furthermore, this process type enables …
Research Summary Report of C06
Integration of Additive Manufacturing in the Construction Process [13.06.2024] Mawas, Karam; Doctoral researcher, k.mawas@tu-braunschweig.de, TU Braunschweig, Institute of Geodesy and Photogrammetry (IGP) Gerke, Markus; Project leader, m.gerke@tu-braunschweig.de, TU Braunschweig, Institute of Geodesy and Photogrammetry (IGP) Maboudi, Mehdi; Associated scientist, m.maboudi@tu-braunschweig.de, TU Braunschweig, Institute of Geodesy and Photogrammetry (IGP) Quality control plays a pivotal role in enabling the seamless integration of components into objects. To ensure adherence to a resilient process and the faithful realization of the designed model in the printed object, it is essential to implement continuous and automated data capture and process inspection. Based on the outcomes of our quality control measures, we investigated how to integrate these practices into Construction Industry 4.0. We will continue …
Research Summary Report of A01
Particle-Bed 3D Printing by Selective Cement Activation (SCA) – Particle Surface Functionalisation, Particle-Bed Compaction and Reinforcement Implementation [14.06.2024] Meier, Niklas; Researcher, niklas.meier@tu-braunschweig.de Zetzener, Harald; Leading researcher, h.zetzener@tu-braunschweig.de Kwade, Arno; Project Leader, a.kwade@tu-braunschweig.de all: TU Braunschweig, Institute for particle technology The fundamental goal of project A01 is to understand material process interactions in particle-bed 3D printing by Selective Cement Activation (SCA). In SCA, a particle-bed consisting of fine aggregates and cement is applied layerwise. Inbetween the layerwise application, a liquid is applied selectively on the upper layer of the particle-bed. Thereby, a the cement hydration reaction is induced locally and the particle-bed hardens at the desired places. In the second funding period of this project, there is a focus on …
Research Summary Report of C04
Integrating Digital Design and Additive Manufacturing through BIM-Based Decision Support and Digital Twin Methods [07.06.2024] Li, Chao; doctoral researcher, chao1.li@tum.de Petzold, Frank; PL, petzold@tum.de Technical University of Munich, TUM School of Engineering and Design, Chair of Architectural Informatics Project C04-WP1 aims to conceive a design decision support system (DDSS) to integrate AM technologies in the early design phase. Project C04 has formalized a ontology-based knowledge base, enabling analysis of AM for building design regarding geometric and functional conformity. The DDSS will be strengthened by implementing the case-based reasoning (CBR) method to integrate AM experts’ know-how, experience, and practical examples into the architectural design process. Summary How to capitalize multi-domain expertise in a BIM-based design workflow, and how to …
Research Summary Report of C03
Integration of Passive and Active Functions in Additively Manufactured Construction Elements [29.05.2024] Auer, Thomas; PL, thomas.auer@tum.de * Briels, David; doctoral researcher, david.briels@tum.de * Nouman, Ahmad; doctoral researcher, ahmad.nouman@tum.de * * Technical University of Munich, TUM School of Engineering and Design, Chair of Building Technology and Climate Responsive Design In engineering advancements, Additive Manufacturing in Construction (AMC) represents a significant paradigm shift. To fully harness the capabilities of AMC, our project, C03, is dedicated to fundamentally transforming the design of building elements. Additive Manufacturing (AM) facilitates the creation of highly specialized components that enhance both passive and active functionalities within buildings. It includes aspects of building physics, such as heat transfer and acoustics, and building services, such as heating, cooling, …
Digital Concrete 2024
Announcement: 4th RILEM International Conference on Concrete and Digital Fabrication We are thrilled to announce the 4th RILEM International Conference on Concrete and Digital Fabrication (Digital Concrete 2024), taking place from September 4-6, 2024, in Munich. Hosted by the Collaborative Research Centre TRR 277, Technical University of Braunschweig, and Technical University of Munich, this event will showcase cutting-edge advancements in concrete additive manufacturing and sustainable digital workflows. Join researchers, engineers, architects, and industry leaders in Munich for this pioneering event. For more information and registration, visit Digital Concrete 2024. https://amc-trr277.de/wp-content/uploads/2024/06/DC_2024_Teaser3_Speaker_Tittelboom.mp4 Plenary Speaker Kim Van Tittelboom https://amc-trr277.de/wp-content/uploads/2024/06/DC_2024_Teaser2_Speaker_Wolfs.mp4 Plenary Speaker Rob Wolf
Research Summary Report of A04
Integrated Additive Manufacturing Processes for Reinforced Shotcrete 3D Printing (SC3DP) Elements with Precise Surface Quality [24.05.2024] Böhler, David1; doctoral researcher, d.boehler@ibmb.tu-bs.de Rudolph, Jennifer1; doctoral researcher, j.rudolph@ibmb.tu-bs.de Freund, Niklas1; doctoral researcher, n.freund@ibmb.tu-bs.de Lowke, Dirk2; project leader, lowke@tum.de 1TU Braunschweig, Institute of Building Materials and Concrete Construction and Fire Safety (iBMB) 2TU Munich, Department of Materials Engineering Main Goal Project A04 investigates cooperative Additive Manufacturing (AM) processes based on Shotcrete 3D Printing (SC3DP). The aim of this project is a fundamental understanding of the SC3DP technology to manufacture sustainable, multi-objective optimised, reinforced concrete components with geometrically precise surface quality and improved building physics by functional integration. Current state of research 3D concrete printing (3DCP) has the potential to significantly …
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 [02.05.2024] Riegger, Felix; Doctoral researcher; Felix.Riegger@iwb.tum.de Baehr, Siegfried; Head of the research group; Siegfried.Baehr@iwb.tum.de All: Technical University of Munich, Institute for Machine Tools and Industrial Management Main Goal To enable selective paste intrusion (SPI) for practical applications, the inclusion of reinforcement is mandatory. The focus of the first funding period was set on implementing reinforcements in SPI parts by using wire arc additive manufacturing (WAAM). During the first funding period, two main issues were identified: the need for increased ecological sustainability for the combined process of SPI+WAAM and accelerated process velocities to improve the economic efficiency. Therefore, the main …
