Kessler, Stephan Dipl.-Ing. Archives - Additive Manufacturing in Construction (AMC) TRR277 https://amc-trr277.de/trr277-person/dipl-ing-stephan-kessler/ AMC TRR 277 Wed, 08 Jan 2025 13:07:40 +0000 en-US hourly 1 https://wordpress.org/?v=6.8.5 Project A 03 https://amc-trr277.de/projects/project-area-a/focus-area-project-a03/ Fri, 19 Nov 2021 15:20:01 +0000 http://amc-trr277.de/?post_type=projects&p=3412 The post Project A 03 appeared first on Additive Manufacturing in Construction (AMC) TRR277.

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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

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Project leader

Bos, Freek PhD M.Sc.

Team Leader for Extrusion-Based Additive Manufacturing of Concrete at the TUM School of Engineering and Design

Project(s)

Project A 03

Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement

Prof. Dr.-Ing. Johannes Fottner

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Project leader

Fottner, Johannes Prof. Dr.-Ing.

Project leader in A03 and B02. He instructs and supports the academic staff regarding bulk conveying and machine design questions.

Project(s)

Project A 03

Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement

Prof. Dr.-Ing. Christoph Gehlen

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AMC Board
Project leader

Gehlen, Christoph Prof. Dr.-Ing.

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)

Project A 02

Particle-Bed 3D Printing by Selective Cement Paste Intrusion (SPI) – Particle Surface Functionalisation, Particle Synthesis and Integration of WAAM Reinforcement

Project A 03

Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement

Contributors

M. Sc. Shengbo Cheng

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Cheng, Shengbo M. Sc.

is a research associate at TUM School of Engineering and Design. He works on structural analysis of functional graded concrete produced by near-nozzle mixing system in A03 and is responsible for evaluating the properties of graded concrete by means of experiments and modelling.

Project(s)

Project A 03

Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement

M. Sc. Maximilian Dahlenburg

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Dahlenburg, Maximilian M. Sc.

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)

Project A 03

Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement

M. Eng. Benedikt Grimm

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Grimm, Benedikt M. Eng.

is a doctoral researcher at the Centre for Building Material within TUM. He is responsible for the further development of the material established in the first project phase of A03. He further analysis all data, prepares reports, presentations and publications.

Project(s)

Project A 03

Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement

M. Sc. Maximilian Hechtl

See profile

Hechtl, Maximilian M. Sc.

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)

Project A 03

Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement

Dr.-Ing. Thomas Kränkel

See profile

Kränkel, Thomas Dr.-Ing.

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)

Project A 02

Particle-Bed 3D Printing by Selective Cement Paste Intrusion (SPI) – Particle Surface Functionalisation, Particle Synthesis and Integration of WAAM Reinforcement

Project A 03

Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement

M. Sc. Michael Unterreiner

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Unterreiner, Michael M. Sc.

has a background in industrial engineering and biomimetics. Currently he is a doctoral student at the Chair of Materials Handling, Material Flow, Logistics within TUM and is responsible for the design, automation, and advancement of the near-nozzle continuous mixing system that was developed during the first project phase of A03.

Project(s)

Project A 03

Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement

Related Publications

Properties of the transition region in 3D printed functionally graded concrete through Near Nozzle Binder-Aggregate Mixing (NNBAM)

2026 | S. Cheng, B. Grimm, M. Unterreiner, M. Hechtl, M. Dahlenburg, T. Kränkel, J. Fottner, C. Gehlen, F. Bos: Properties of the transition region in 3D printed functionally graded concrete through Near Nozzle Binder-Aggregate Mixing (NNBAM) Construction and Building Materials, Volume 520. 2026, https://doi.org/10.1016/j.conbuildmat.2026.145990

Data | Zenodo, 2026, https://doi.org/10.5281/zenodo.18899746

Workflow for geometric evaluation, mechanical testing and simulation of DED-Arc additively manufactured high-strength low-alloy steel components for local buckling

2025 | M. Müggenburg, H. Jahns, K. Thiele, J. Müller, J. Hensel, J. Unglaub: Workflow for geometric evaluation, mechanical testing and simulation of DED-Arc additively manufactured high-strength low-alloy steel components for local buckling Structures, 2025, https://doi.org/10.1016/j.istruc.2025.108374

Data | Zenodo, 2025, https://doi.org/10.5281/zenodo.14205492.

Virtual Prototyping mit DEM zur Entwicklung eines Near-Nozzle-Mixing Verfahrens für den additiven 3D Betondruck für den Roboter Einsatz

2021 | Tan, Y.; Dahlenburg, M.; Kessler, S.; Fottner, J.: Virtual Prototyping mit DEM zur Entwicklung eines Near-Nozzle-Mixing Verfahrens für den additiven 3D Betondruck für den Roboter Einsatz. In: 25. Fachtagung Schüttgutfördertechnik. OVGU Magdeburg, 2021.

Interlayer Reinforcement Combined with Fiber Reinforcement for Extruded Lightweight Mortar Elements

2020 | Matthäus, C.; Kofler, N.; Kränkel, T.; Weger, D.; Gehlen, C.: Interlayer Reinforcement Combined with Fiber Reinforcement for Extruded Lightweight Mortar Elements. In: Materials 2020, 13, 4778, 2020. – DOI: https://doi.org/10.3390/ma13214778.

More projects of
Focus Area A

Project A 01

Particle-Bed 3D Printing by Selective Cement Activation (SCA) – Sustainability, process enhancement and material models

Project A 02

Particle-Bed 3D Printing by Selective Cement Paste Intrusion (SPI) – Particle Surface Functionalisation, Particle Synthesis and Integration of WAAM Reinforcement

Project A 04

Integrated Additive Manufacturing Processes for Reinforced Shotcrete 3D Printing (SC3DP) Elements with Precise Surface Quality

Project A 05

Integration of Individualized Prefabricated Fibre Reinforcement in Additive Manufacturing with Concrete

Project A 06

Laser Powder-Bed Fusion (LPBF) of Steel Elements for Construction – Basics of Design and Mechanical Resilience.

Project A 07

Wire and Arc Additive Manufacturing (WAAM) of Complex Individualized Steel Components

Project A 08 (completed)

Structural Timber by Individual Layer Fabrication (ILF)

Project A 09

Injection 3D Concrete Printing (I3DCP) – Material Efficient Lightweight Reinforced Concrete Structures Based on Spatially Complex Strut-and-Tie-Models

Project A 10

Earth Additive Manufacturing (EAM) – Material and Process Combinations for AM with Earth-based Materials

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]]> Dipl.-Ing. Stephan Kessler https://amc-trr277.de/trr277-people/dipl-ing-stephan-kessler/ Thu, 25 Nov 2021 16:23:18 +0000 http://amc-trr277.de/?post_type=person&p=3600 Head of the workgroup bulk conveying and supports Prof. Fottner in leading project A03 and B02.
He instructs and supports the academic staff regarding DEM-solutions, 3D-CAD design of machines and virtual prototyping questions to create a digital twin.

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Dipl.-Ing. Stephan Kessler

Current location: TU München
Institute: Chair of Material Handling, Material Flow, Logistics

stephan.kessler@tum.de

Head of the workgroup bulk conveying and supports Prof. Fottner in leading project A03 and B02.
He instructs and supports the academic staff regarding DEM-solutions, 3D-CAD design of machines and virtual prototyping questions to create a digital twin.

Publications

2021 | Tan, Y.; Dahlenburg, M.; Kessler, S.; Fottner, J.: Virtual Prototyping mit DEM zur Entwicklung eines Near-Nozzle-Mixing Verfahrens für den additiven 3D Betondruck für den Roboter Einsatz. In: 25. Fachtagung Schüttgutfördertechnik. OVGU Magdeburg, 2021.

The post Dipl.-Ing. Stephan Kessler appeared first on Additive Manufacturing in Construction (AMC) TRR277.

]]> Virtual Prototyping mit DEM zur Entwicklung eines Near-Nozzle-Mixing Verfahrens für den additiven 3D Betondruck für den Roboter Einsatz https://amc-trr277.de/amc-publikation/virtual-prototyping-mit-dem-zur-entwicklung-eines-near-nozzle-mixing-verfahrens-fur-den-additiven-3d-betondruck-fur-den-roboter-einsatz/ Thu, 20 Jan 2022 15:34:50 +0000 http://amc-trr277.de/?post_type=amc-publikation&p=4583 2021 | Tan, Y.; Dahlenburg, M.; Kessler, S.; Fottner, J.: Virtual Prototyping mit DEM zur Entwicklung eines Near-Nozzle-Mixing Verfahrens für den additiven 3D Betondruck für den Roboter Einsatz. In: 25. Fachtagung Schüttgutfördertechnik. OVGU Magdeburg, 2021.

The post Virtual Prototyping mit DEM zur Entwicklung eines Near-Nozzle-Mixing Verfahrens für den additiven 3D Betondruck für den Roboter Einsatz appeared first on Additive Manufacturing in Construction (AMC) TRR277.

]]> 2021 | Tan, Y.; Dahlenburg, M.; Kessler, S.; Fottner, J.: Virtual Prototyping mit DEM zur Entwicklung eines Near-Nozzle-Mixing Verfahrens für den additiven 3D Betondruck für den Roboter Einsatz. In: 25. Fachtagung Schüttgutfördertechnik. OVGU Magdeburg, 2021.

The post Virtual Prototyping mit DEM zur Entwicklung eines Near-Nozzle-Mixing Verfahrens für den additiven 3D Betondruck für den Roboter Einsatz appeared first on Additive Manufacturing in Construction (AMC) TRR277.

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