Research Summary Report
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 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 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 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 …
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 …
Research Summary Report C02
3D Structural Puzzle – Numerical Multi Scale Shape and Topology Optimisation Methods to Additively Manufacture Optimal Structures from Optimised Pieces [27.01.2022] Bletzinger, Kai-Uwe: Project Leader Najian Asl, Reza: Post-Doc Research Associate TU Munich, Chair of Structural Analysis Summary This project deals with structures considered as large 3D puzzles and multi scale optimization aspects. The goal is to create optimized individual structural pieces which are subsequently assembled to form an overall optimal structure. Additive manufacturing is the ideal meaning of greatest potential to combine industrial efficient production with individual design and structural layout. The main research question is to develop numerical, simulation-based optimization methods which allow for the design and creation of large, additively manufactured structures to be carried out …
Research Summary Report C04
Integrating Digital Design and Additive Manufacturing through BIM-Based Decision Support and Digital Twin Methods [05.03.2021] Li, Chao; Doctoral researcher; chao1.li@tum.deTU Munich, Chair of Architectural Informatics Slepicka, Martin; Doctoral researcher; martin.slepicka@tum.deTU Munich, Chair of Computational Modeling and Simulation In the context of AMC, C04 workgroups attempt to cohesively integrate AM and BIM–based early design, through the design decision support and fabricationenhanced multi–LOD BIM models.Knowledge Base Formalization Domain–specific knowledge base usually serves as a backbone in a Knowledge–Based System (KBS).Furthermore, the knowledge base of proposed DDSS has to be formalized in an extensible, reusable and interoperable manner. In the first stage of work, C04 workgroups have conducted semi–structured interviews between other sub–projects (A01–A05, C01–C06). From the interviews, four groups of knowledge …
Research Summary Report A02
Particle-Bed 3D Printing by Selective Cement Paste Intrusion (SPI) – Particle Surface Functionalisation, Particle Synthesis and Integration of WAAM Reinforcement [26.02.2021] Hamilton, Leigh Duncan; Researcher, leigh-duncan.hamilton@tu-bs.de Breitung-Faes, Sandra; Leading Researcher, s.breitung@tu-bs.de Kwade, Arno; PL, a.kwade@tu-bs.de All: TU Braunschweig, Institute for Particle Technology (iPAT) Selective cement paste intrusion (SPI) is an additive manufacturing method where aggregate particles are spread in small layers, followed by the local intrusion of the cement paste into the aggregate layers. These steps are repeated layer-by-layer and the consequent hardening forms the structure. In comparison to other AM processes, the necessity of support structures for cantilevers is redundant for SPI. In addition, research to date has shown that SPI-made components closely acquire isotropic compressive strength (>70 …
Research Summary Report A06
Integration of Individualized Prefabricated Fibre Reinforcement in Additive Manufacturing with Concrete [19.02.2021] Rothe, Tom; Doctoral researcher, t.rothe@tu-bs.de, TU Braunschweig, Institute of Mechanics and Adaptronics (IMA) Hühne, Christian; Project leader, christian.huehne@dlr.de, TU Braunschweig, Institute of Mechanics and Adaptronics (IMA) One of the biggest challenges in 3D printing with cementitious materials is the integration of reinforcement. The project aims to develop textile-based reinforcement strategies for additive manufacturing with concrete and to utilize the advantages of textile reinforcement (e.g. corrosion resistance and material flexibility) for the production of material-efficient, individualized structures. These structures should be produced by a robotic winding process, which provides a high degree of freedom in shaping in combination with a minimal amount of tooling and formwork. To be …
Research Summary Report A06
Laser Powder-Bed Fusion (LPBF) of Steel Elements for Construction – Basics of Design and Mechanical Resilience. [12.02.2021] Diller, Johannes; Doctoral researcher; Johannes.Diller@tum.de, Dorina Siebert, Doctoral researcher; dorina.siebert@tum.de TU Munich, Chair of Metal Structures Wenzler, David; Doctoral researcher; David.Wenzler@iwb.tum.de, Kolb, Cara; Doctoral researcher; Cara.Kolb@iwb.mw.tum.de TU Munich, Institute for Machine Tools and Industrial Management The reproducibility of the mechanical properties of PBF-LB/M parts needs to be increased. This requires a more detailed understanding of the correlation between the process parameters and the mechanical and metallurgical properties of the manufactured parts. In project A06 a first step towards this goal has been taken: With a thermography camera, the cooling rates during the fabrication of fatigue test specimens were measured. Two process parameter …
Research Summary Report A07
Wire and Arc Additive Manufacturing (WAAM) of Complex Individualized Steel Components [29.01.2021] Unglaub, Julian, Associate Researcher, Institute of Steel Structures Jahns, Hendrik, PhD Researcher, Institute of Steel Structures Thiele, Klaus, Project Leader, Institute of Steel Structures Project A07 investigates structural design, WAAM methods and component testing of complex, large-scale, individualized steel components. The objective is to connect conventionally manufactured steel components and semi-finished products with additively manufactured, complex steel components The Institute of Steel Structures develops a novel test method based on fill field strain data. This test method considers potentially anisotropic component behaviour, surface topographies, geometric irregularities and residual stresses in addition to the relevant material properties. Fig 1: Tension specimen with combined extensometer and DIC measurement …
Research Summary Report A08
Structural Timber by Individual Layer Fabrication (ILF) [22.01.2021] Bunzel, Frauke; Project leader; frauke.bunzel@wki.fraunhofer.de Asshoff, Carsten; Doctoral researcher; carsten.asshoff@wki.fraunhofer.de Fraunhofer Institute for Wood Research Wilhelm-Klauditz-Institut WKI In order to produce future-oriented timber structures in the building industry that meet the requirements of ecological and economic sustainability, an additive manufacturing process with wood chips is being developed using the new approach of individual layer fabrication (ILF). In first steps, established wood chip fractions and adhesive systems from the wood-based materials industry are used e. g. for particleboards or oriented strand boards. For an acceptable adhesive-wood-chips ratio the amount of adhesive must be as low as possible, which is one of the challenges in developing ILF, see Fig. 1. In addition to …
