Networking with other projects

Poster

In recent years, research and development of Additive Manufacturing (AM) in the domain of architecture, engineering, and construction has greatly increased, with a large variety of process technologies, but with a strong focus on cementitious materials. While such additive processes allow for zero-waste production and the overall minimization of material consumption, the primary use of cement-based products still brings with it concerns of remaining environmental impacts in terms of high CO2 emissions, high embodied energy, and depletion of natural resources. These concerns are motivating the exploration of earthen materials as an alternative to cement-based construction methods and the re-approach to earthen materials and historic earth building methods in novel Earth Additive Manufacturing (EAM) processes. Earth-based materials are traditionally made from variable mixtures of clays, which act as a binder in the mixture, aggregates, and water, with optional additions of natural fibres, e.g., straw or hemp.

Aim

The main objective of this research is the conception and investigation of EAM processes, based on the characterization of earth-based material mixtures for two novel processes, namely a) Sprayed Earth Additive Manufacturing (SEAM) as a deposition-based EAM process, and b) Intrusion Earth Additive Manufacturing (IEAM) as a particle-bed-based EAM process, and their evaluation in large-scale architectural applications. Expected outcomes of the research, based on the WPs, are: Firstly, the investigation of the applicability of various earth-based materials for AM processes as well as the general characterization of earth-based binders and material mixtures for EAM in terms of their pumpability, buildability, shrinkage behaviour, and compressive strength. Secondly, the design and implementation of two exemplary EAM processes and exploration of different earth-based binders and material combinations therein. Lastly, the exploration of these EAM technologies for geometrically differentiated architectural components that can combine insulation and load transfer, and the validation of the proposed technologies through exemplary fabrication experiments and demonstrators at full construction scale.

Networking with other projects

To fundamentally investigate the potentials of EAM, this research project is strongly linked to other research areas within the TRR 277: Firstly, to projects developing concrete AM technology in Focus Area A, in particular A04, to transfer knowledge gained in SC3DP to earth spraying, and A02, respectively, to transfer knowledge gained in SPI to earth intrusion, as well as A03, to evaluate near-nozzle mixing systems for both processes. In return, the cement reduction potential using calcined clays will feed back to these projects and benefit them accordingly. Another opportunity within Focus Area A is an association between A10 and A05, in which the applicability of fibre reinforcement in EAM can be explored. Secondly, this project aims to create links to projects in Focus Area B, in particular with B05, in which process-related design limitations of spraying earthen materials could be overcome by the implementation of mobile robots. Thirdly, the general applicability of EAM for the building scale is examined in collaboration with projects of Focus Area C. Here, a special focus is given to the evaluation of the building physics potential (with C03), the possibility of component prefabrication and jointing techniques (with C05), as well as the evaluation of the ecological sustainability potential (with C09). These links aim to work as an interaction and mutual feedback for the fundamental advancement of each of the individual research projects. In addition, project A10 cooperates with Project Ö through technical consulting and sharing of research results toward the development of learning activities. Results of the learning activities are reflected back to A10 by Project Ö.

Networking with other projects

Poster

TRR277_B05_Poster_1-DFG-Begutachtung
TRR277_B05_Poster_2-DFG-Begutachtung

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 is used to investigate AM strategies for mobile robots. By implementing advanced sensor and control solutions, autonomous localization and precise manipulation techniques for mobile AM are explored with the aim of manufacturing large building components whose size exceeds the robot’s static workspace. Additionally, this research aims to provide scalability to AM processes by examining the use of multiple robots to cooperate on individual manufacturing jobs.

Objective

The main objective of this research is the conception and development of building-scale AM technology using mobile robots to study various architectural application scenarios. While current systems for in situ AM are often single stationary large-scale facilities, AM using mobile robots could offer a less constrained workspace and thus new architectural possibilities. They could offer scalability through collaboration and parallelization of both mobile multi-robot systems and human-robot teams. Finally, their flexibility in deployment could extend the scope of in situ AM from new construction to constructions within existing contexts.

Approach

To carry out this research, two mobile platforms are designed and set up to be capable of omni-directional ground-based movements with four steerable wheels and material extrusion heights of 2.5 m with a 6DOF robotic manipulator on a vertical linear axis. The mobile systems can further be equipped with either an onboard clay or tethered concrete extrusion 3D printing system, enabling the testing and validation of the proposed principles and methods in a laboratory environment. With the two identical systems, planned is to perform experiments with both a stepwise print-drive-print (phase 1) and a continuous print-while-drive (phase 2) approach, with the aim of creating building-scale components using coordination of tasks and cooperative behaviour with cooperating machines and humans. In this scope, a two-step on-board localization and end-effector positioning method is proposed, where firstly the mobile platform is globally located in a world map and secondly the global localization is refined by referencing the robot locally, i.e., relative to the workpiece.

Networking with other projects

This research project is strongly linked to other research areas within the TRR 277: Firstly, to the concrete extrusion AM technology developed within the research project A03; secondly, to the integration of streamlined design-to-fabrication workflows developed in C04; thirdly, to the process control and online feedback mechanisms during fabrication for robots with extended degrees of freedom developed in B04, including methods for the robot’s localization on-site; and finally to the integration of AM in the construction process using mobile robots directly on building sites, which is investigated in the research project C06.

TRR 277 AMC researches innovative additive manufacturing methods, materials, and optimized designs and processes to increase sustainability in construction. These innovations will change the field of construction and its future toward digitalization, saving energy and resources while increasing productivity. The changes in the field will result in new job profiles with opportunities for closing the gender gap in construction.

To achieve this, it is vital to create opportunities for youth and the general public to engage with additive manufacturing in construction (AMC). The aims of the project Ö are
1) to empower the next generation – especially young women and girls – to see themselves in and to shape the future of construction;
2) to facilitate learning about innovative AMC research; and
3) to raise awareness of the importance of sustainability in construction among all youth and other target groups.

To achieve these goals, the project combines public relations work with learning sciences research to develop the AMC Edu:Lab, a learning space for active engagement with AMC research and innovation.

Central Tasks (CT) is dealing with day-to-day-management of the TRR 277 AMC.

The CT Office supports the spokesperson Harald Kloft and co-spokesperson Kathrin Dörfler in managing and accounting for funds, convening AMC board meetings and general meetings, and coordinating general public relations. CT also coordinates networking among research projects, fund allocation and procurement, monitors AMC progress and milestones, and organizes scientific events and prepares reports and proposals. The Central Task Office reports to the AMC Board.

leads the scientific staff in the conception and execution of the research, and in questions of validation of the proposed methods. She is also responsible for the coordination of the cooperating research projects in the TRR 277. She is the Co-Spokesperson of the TRR 277.

Dörfler supports Kloft as contact person for the DFG, in general public relation matters and also in representing the TRR 277 externally. Internally, Dörfler assists Kloft in the coordination between the research projects, as well as in the decisions on the financing of research tasks in the TRR 277.