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Research Summary Report A06
Laser Powder-Bed Fusion (LPBF) of Steel Elements for Construction – Basics of Design and Mechanical Resilience [03.06.2022] 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 will be investigated and correlations will be determined. In the first funding period, the project is focused on analyzing small-scale …
Research Summary Report A04
Integrated Additive Manufacturing Processes for Reinforced Shotcrete 3D Printing (SC3DP) Elements with Precise Surface Quality [25.05.2022] David, Martin; Doctoral Researcher, m.david@tu-braunschweig.de TU Braunschweig, Institute for Machine Tools and Production Technology (IWF) Project A04 aims to investigate 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 geometrical 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. Hereby, different robot guided end effectors are used for flexible and automated processes. Summary Within SC3DP many process parameters, like volume of sprayed concrete, air volume flow, nozzle to strand distance and …
Research Summary Report A07
Wire and Arc Additive Manufacturing (WAAM) of complex individualized steel components [20.05.2022] Jahns, Hendrik; Doctoral researcher Unglaub, Julian, Senior researcher Institute of Steel Structures, Technische Universität Braunschweig In project A07 the design, manufacturing and mechanical performence of complex individualized WAAM steel nodes for use in construction is investigated. A new method is developed to design force flow optimized steel nodes as connectors between semi-finished parts and anchorage structures considering the manufacturing possibilities of the WAAM-process and the resulting material behaviour. The manufacturing possibilities will be identified by case study demonstrators, which represent occurring features of the designed node. The produced parts are characterized regarding their mechanical properties. For that an advanced material testing method was developed to evaluate the potentially …
Research Summary Report A08
Structural Timber by Individual Layer Fabrication (ILF) [13.05.2022] Asshoff, Carsten; Doctoral researcher;carsten.asshoff@wki.fraunhofer.de Fraunhofer Institute for Wood Research Wilhelm-Klauditz-Institut WKI 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 investigated. Finally, multiple demonstrators are fabricated for showcase purposes. Summary Working group Bunzel is researching the process …
Research Summary Report B04
Process Control and Adaptive Path Planning for Additive Manufacturing Processes Based on Industrial Robots with an Extended Degree of Freedom [06.05.2022] 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 qualities are a major challenge, 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 …
Spring fever in the AMC
At the cross-project workshop in Munich, the subprojects were able to get closer during slow dating. At the end of April, 75 scientists of the Collaborative Research Center Transregio 277 Additive Manufacturing in Construction (AMC) met in Munich to determine in-depth cooperation possibilities of their subprojects and to define the orientation of the AMC for the 2nd funding phase. The focus of the two days was on networking within the AMC. The subprojects of the Focus Areas A, B and C met in so-called “slow dates” every 30 minutes to define and determine common points of contact and meaningful collaborations. The focus was less on as many collaborations as possible, but more on the quality of the networking and the …
Research Summary Report C06
Integration of Additive Manufacturing in the Construction Process [29.04.2022] Mawas, Karam; Doctoral researcher Gerke, Markus; Project leader Maboudi, Mehdi; Associated scientist Riedel, Björn; Associated scientist all: TU Braunschweig, Institute of Geodesy and Photogrammetry (IGP) In order to ensure a robust process is followed and the printed object adheres faithfully to the designed model, continuous and automatic data capturing and inspection of the process is required. As a result, quality control would ensure the original vision of the designer comes to light and that the combination of components into objects actually would work. Summary Digital fabrication is a design and manufacturing workflow where digital data directly drives manufacturing equipment to form various part of geometries on demands using digital data. …
Research Summary Report A07
Wire and Arc Additive Manufacturing (WAAM) of complex individualized steel components [22.04.2022] Müller, Christoph; doctoral researcher, TU Braunschweig, Institute for Structural Design (ITE) 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 restrains are fabricated. Furthermore a novel approach for material and component testing is developed to identify local material and component properties. Summary In the regularly published literature on additive manufacturing, the fabrication …
Research Summary Report A03
Extrusion of Near-Nozzle Mixed Concrete – Individually Graded in Density and in Rate of 3D Fibre Reinforcement [15.04.2022] Authors: Dahlenburg, Maximilian; Researcher Fottner, Johannes; Project Leader all: TUM, Chair of Materials Handling, Material Flow, Logistics A03 has the main goal to make graded concrete extrusion possible. Therefor an innovative near-nozzle-mixing system is being developed, optimized, and tested. Summary The evolution of 3D-concrete printing is advancing at a fast pace worldwide due to the great potential of these technologies regarding time-, resource efficiency and sustainability. This project focuses on enabling graded concrete extrusion by manipulating material properties in-situ. Furthermore, it targets to handle general additive manufacturing (AM) problems with concrete regarding limitations in the material design. In state-of-the-art concrete printers material …
Research Summary Report A01
Particle-bed 3D printing by selective cement activation: Particle surface functionalization, particle bed compaction and reinforcement [12.04.2022] Authors: Meier, Niklas; Researcher, Zetzener, Harald; Leading researcher, Kwade, Arno; Project Leader, all: TU Braunschweig, Institute for particle technology The main goal of our research at A01 is to improve the mechanical strength and shape accuracy of the printed concrete parts as well as the printing speed. While the project partner iBMB focuses on the material-process interaction, the work packages performed at the iPAT are targeted at improving the powder properties. Summary To reach higher mechanical strengths, one approach is to increase the packing density of the powder and therefore the density of the final part. Therefore the particle surfaces are modified, for …
Research Summary Report C04
Integrating Digital Design and Additive Manufacturing through BIM-Based Decision Support and Digital Twin Methods [25.03.2022] 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 The application of Additive Manufacturing (AM) methods in the construction process requires the careful consideration of its applicability and the necessary boundary conditions in the early design phase of construction. Project C04-WP1 aims to conceive a design decision support system (DDSS) to integrate AM technologies in the early design phase. The DDSS allows the analysis of the early-stage building design regarding the geometric features and functional properties of the individual components and provide recommendations for the manufacturing method. Summary Consideration of …
Research Summary Report A04
Integrated Additive Manufacturing Processes for Reinforced Shotcrete 3D Printing (SC3DP) Elements with Precise Surface Quality [18.03.2022] Freund, Niklas; doctoral researcher, n.freund@ibmb.tu-bs.de Vandenberg, Aileen; postdoctoral researcher, a.vandenberg@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) Project A04 aims to investigate 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 geometry 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 Within SC3DP, concrete has a duality to the special requirements that are placed on it. On one hand, …
Research Summary Report C03
Integration of Passive and Active Functions in Additively Manufactured Construction Elements [11.03.2022] Briels, David; doctoral researcher, david.briels@tum.de Nouman, Ahmad; doctoral researcher, ahmad.nouman@tum.de Auer, Thomas; PL, thomas.auer@tum.de …
Research Summary Report A02
Particle-Bed 3D Printing by Selective Cement Paste Intrusion (SPI) – Particle Surface Functionalisation, Particle Synthesis and Integration of WAAM Reinforcement 04.03.2022 Riegger, Felix; Doctoral researcher, Wimmer, Andreas; Head of the research group All: Technical University of Munich, Institute for Machine Tools and Industrial Management The main goal of the 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 negatively affects the paste …
Research Summary Report B05
Principles of Mobile Robotics for Additive Manufacturing in Construction 01.03.2022 Dielemans, Gido; Doctoral researcher, Technical University of Munich, Department of Architecture, TT Professorship Digital Fabrication 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 on single fabrication jobs. …
Research Summary Report A08
Structural Timber by Individual Layer Fabrication (ILF) [18.02.2022 ] Buschmann, Birger; Doctoral researcher, birger.buschmann@tum.de, Technical University of Munich, Chair of Timber Structures and Building Construction 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 investigated. Finally, multiple demonstrators are fabricated for showcase purposes. Summary Within …
AMC Tour First Take – Munich in February
In mid-February, the AMC office had the chance to meet with some of the subprojects based at the TU Munich. Anne Niemann, Jeldrik Mainka and Meike Bährens took the opportunity, away from a formal conference and the time constraints of other meetings, to take a closer look at various projects from Focus Area A and subproject B05 from Focus Area B and to engage in scientific dialogue with the researchers. The office would like to thank all participants for the exciting insights, the smooth organization and the extremely interesting discussions.
Research Summary Report C06
Integration of Additive Manufacturing in the Construction Process [11.02.2022] Placzek, Gerrit; Doctoral researcher, g.placzek@tu-braunschweig.de, TU Braunschweig, IBB 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 a 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 develop production systems for the construction industry 4.0. Summary Currently, one of the most followed approaches is to …
Research Summary Report A07
Wire and Arc Additive Manufacturing (WAAM) of Complex Individualized Steel Components [04.02.2022 ] Müller, Johanna; doctoral researcher, johanna.mueller@tu-braunschweig.de, TU Braunschweig, Institute of Joining and Welding 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 restrains 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 within the TP …
Research Summary Report C05
Jointing Principles for Combination of Concrete Elements Produced by Different Additive Manufacturing Processes [28.01.2022] Empelmann, Martin; Project Leader, m.empelmann@ibmb.tu-bs.de Lanwer, Jan-Paul; Doctoral Researcher, j.lanwer@ibmb.tu-bs.de TU Braunschweig, Institute of Building Materials, Concrete Construction and Fire Safety (iBMB), Division of Concrete Construction The main goal of the C05 project is to investigate the correlation between the execution and manufacturing of joints on the load-bearing behaviour of dry joints in AM concrete elements. Fundamental knowledge will be gained for the design of resource-efficient AM components and their application in construction. Summary The first summary report of C05 contained an evaluation strategy to gather, design and select appropriate joint profiles for the connection between elements produced by different additive manufacturing processes. Fig. 1 …
