Project A 03
Networking with other projects
Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement
The gradation of material properties in concrete extrusion allows more efficient use of resources and multifunctional design of components, but represents a particular challenge in pump-based extrusion systems. Therefore, an innovative near-nozzle mixing system, called gradation ready extruding system (GRES), is being developed in A03 which enables immediate gradation of the material properties. This allows to locally extrude different materials ranging from normal to lightweight concrete. Furthermore, the short conveying distances for the fresh concrete facilitate the extrusion of e.g. more sustainable materials that cannot be processed in previous extrusion systems due to impeded workability compared to normal 3D printing materials. The combination of multi-material printing with an automated vertical rebar insertion strives for high performance as well as a precise adjustment of material properties to the local needs and thus for a more sustainable material use.
Aim
Graded Concrete Extrusion
- Design and construction of a gradation ready near-nozzle mixing system and its implementation on an industrial robot
- Development of discrete material gradation (with regard to thermal conductivity, strength, and sustainability)
- Integration of an automated vertical layer reinforcement
- Conception and production of a multi-material construction element
Approach
Experimental investigation and DEM-Simulation
- DEM Simulation for system function validation
- Experiment based development and optimization of process and materials for gradation
- Quantification and validation of material properties for graded concrete extrusion
Networking with other projects
- A02: Construction of a demonstrator combining the technologies
- A04: Collaboration on vertically inserted reinforcement using the same insertion device
- A05: Evaluation of suitable reinforcement strategies
- A08: Construction of a demonstrator combining the technologies
- B04: Collaboration on path planning as well as process and control parameters. Furthermore, collaboration on adaption of insertion device (together with A04)
- B05: Collaboration on extrusion of (lightweight) concrete, e.g. with regard to material development and supply, as well as on robot control
- C01: Thermal and geometrical optimization of a lightweight/graded concrete construction element
- C02: Collaboration on optimization of graded concrete elements; input for simulations
- C03: Thermal and geometrical optimization of a lightweight/graded concrete construction element
- C04: Input for BIM
- C05: Collaboration on dry joints and conception of joints between different AM technologies
- C06: Discussion on pre-fabrication and in-situ manufacturing
- C07: Exchange on requirements for standardization processes
Project leaders
PhD M.Sc. Freek Bos
Team Leader for Extrusion-Based Additive Manufacturing of Concrete at the TUM School of Engineering and Design
Project(s)
Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement
Prof. Dr.-Ing. Johannes Fottner
Project leader in A03 and B02. He instructs and supports the academic staff regarding bulk conveying and machine design questions.
Project(s)
Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement
Prof. Dr.-Ing .Christoph Gehlen
Dean of TUM School of Engineering and Design, Head of cbm and leads project A02 and A03. He instructs and advises the academic staff regarding additive manufacturing and concrete technological questions. He is responsible for the coordination and quality control of all work of cbm. Untill Oct. 2021 he was the co-spokesperson of the TRR 277. He then became Dean of TUM School of Engineering and Design and handed over the tasks of Co-Speaker to Kathrin Dörfler.
Project(s)
Particle-Bed 3D Printing by Selective Cement Paste Intrusion (SPI) – Particle Surface Functionalisation, Particle Synthesis and Integration of WAAM Reinforcement
Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement
Contributors
M. Sc. Maximilian Dahlenburg
is an expert in mechanical engineering, specialized in development, CAD-Design and construction of complex machines at the Chair of Materials Handling, Material Flow, Logistics within TUM. He is responsible for design, construction, automation, simulation and optimization of the near-nozzle continuous mixing system developed in A03. Furthermore he is responsible for the material supply and the mat…
Project(s)
Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement
M. Sc. Maximilian Hechtl
is a research associate at the Working group of Prof. Dr.-Ing. Christoph Gehlen. Expert in material development of Extrusion Concrete for additive manufacturing.
Project(s)
Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement
Dr.-Ing. Thomas Kränkel
Head of workgroup concrete technology and assists Prof. Gehlen in leading project A02. He instructs and supports the academic staff regarding additive manufacturing and concrete technological questions.
Project(s)
Particle-Bed 3D Printing by Selective Cement Paste Intrusion (SPI) – Particle Surface Functionalisation, Particle Synthesis and Integration of WAAM Reinforcement
Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement
