HIGH-PERFORMANCE FREEFORM SPATIAL 3D PRINTING

Written CoC Submitted Document
Research Ethics Application Draft Document

This research aims to embed innovative material research directly into the field of architecture through accessible tools and design for manufacturing workflows

INTRODUCTION TO THE RESEARCH PROBLEM

ICD-ITKE

Continuous fiber composite winding
Highly complex infraestructure needed
Mold constrain - geometrical linear elements
Manufacturing overcost the materials

CMAS-ETH

Newel additive manufacture process
Material interpretation
Focusing on manufaturing technique
Freedom in the output

Composite alocation vs geometry optimization

Material deposition optimization
Standart geometry consolidation
vs
Geometrical optimization
Free form 3d Printing

HYPOTHESIS

Additive fabrication strategies utilizing fabrication informed, material-driven, computational design processes can result in optimized structural models that can handle the manufacturing complexity and cost of composites high-performance materials.

Optimized design workflow with feedback from the 3D deposition, design and fabrication materials, can help to optimize additive processes, resulting in structures with improved self-weight to load-bearing performance as well as lower manufacturing costs.

Research questions

• Are composite materials through additive manufacturing techniques encoded with computational design tools able to be cost-benefit applicable in the construction industry?
• How does architectural design practice change with the possibility of this geometrical freedom?

• Is the current development state of additive manufacturing with continuous fibre, able to produce full architectural elements with embodied structural performance ?
• How can high-performance composites be used in architecture across scales, from single modules to full-size elements?
• How does the newel manufacturing methods used in this research, help in the application of these high-end materials in the construction industry?

RESEARCH FRAMEWORK

The construction industry is among the least digitised sectors in the world and has had the lowest productivity gains of any industry over the past two decades.

One of the key aspects to deal with these challenges, increasing the speed, accuracy and safety whilst reducing cost and waste in the construction industry, is the integration of new and alternative construction methods (CECE, 2019).

Today we are in a position to explore the use of a plethora of new and innovative materials, systems and components that have the potential to lead towards a new paradigm in architecture (Kroner, 1997).

This change of paradigm in architecture has already proven feasible in the academic and research-level where multiple institutions have not only demonstrated the theoretical benefits of digitizing the industry but also built several demonstrators and state of the art pavilions to showcase the potentials of these new technologies.

• For AM to be able to reach ‘volume’ construction or the construction market,it must form part of an integrated, digital continuum of which the performative impact
• Performance-wise on deployment cost and structural improvement/proficiency- outweighs aesthetics alone.

STATE OF THE ART

Summary of research/projects relevant to the thesis, a critical analysis

Branch technologies

• Short fiber AM lattice fabrication as internal structure
• Lighweight lost mold reinforcement
• Geometrical flexibility for ruled surfaces
• No internal cavities

ETH-Mesh Mould

• Metal/plastics lattice mesh as concrete rebar
• Geometrical flexibility for ruled surfaces
• Constrained by concrete particles and leak
• Automated rebar assembly
• Traditionallized usage of lattices/rebars

Shop Architects

• Lattice lighweight structure non continuous materials
• Low perfomance material, high perfomance geometry
• Topological optimized of overal shape

Iridescence Print (2015) by Gramazio Kohler Research

• Highly informed and geometrically complex structures
• Fabrication flexibility and repeateability without molds
• Low performance material and sequencing

FiberBots MitMedialab

• Continuous fiber deposition on reusable mold
• Lowmaterial/geometry optimization
• Low geometrical flexibility

Mataeerial-IaaC

• Material informed fabrication design exploration
• Non structurally performative
• Geometrical ouptut unconstrained

JorisLaarmanLab

• WAM metal printin lattice freedom on geometry
• Constrained by the path fabrication/intersection
• Flexibility on geometry not looking for structural behaviour

CEAD

• AIO system from material to product
• Standart geometrical approach
• Optimization of traditional geometry fabrication

Arevo

• Chopped fiber embodied on layer by layer
• Mold constrained
• Implementation difficulties

CMAS Lab, 9T Labs, ETH Zurich.

• Optimized material
• Non geometrical exploration
• Technical fabrication research

MX3D-bridge

• Performative materials on high stress structures
• Continuous embodied material
• Optimization of overal shapes

Electro impact

• Layer by layer+reinforcement
• Standart geometrical outputs in AM
• Highly complex dual system

Moi composites

• Layer by layer manufacturing/materiality
• Fast deposition capabilities
• Tested on standart reinforced geometries

Continuous composites

• Optimized material-fabrication
• Exploration on manufacturing
• Constrained on lighweightness for aerospatial

ICD, ITKE, TUM 2014

• Mold fabrication inherited from AFP
• Mold bigger than outcome
• Shell composite

ICD, ITKE, TUM 2016

• Highly complex fabrication
• Geometrical design thought overall perfomance
• Geometry constrained to initial mold
• Non shell geometry, full 3d

BUGA Fibre Pavilion 2019

• Reduced fabrication setup
• Reduced geometrical freedom
• Optimized pipelike geometry

Issues from practice

Due to the multidisciplinarity of the research ,a need for some terminology definition have come as an uprising issue.

There are multiple interpretations of some terms depending on the field of study of the baseline literature review. They will be defined and bounded in this thesis framework

RESEARCH DEVELOPMENT

What would bring this technology adoption to architecture will allow us to achieve?

Tools on CF-AM on the field exist but they are not accessible

Small amount of literature related to continuous fiber deposition in design and architecture

Providing access to the tools, the knowledge and the financial means to educate, innovate and invent using technology and digital fabrication to allow anyone to make (almost) anything, and thereby creating opportunities to improve lives and livelihoods around the world.

Fab Foundation motto

A series of material composites space frames artefact and structural probes will be developed

Focusing on the architectural application of this AM technology that allows freeform fabrication not constraining the geometrical arquitectural design as other conventional techniques.

PROBE, DEFINITION AND DEMONSTRATOR

Probing through doing

• Laying out the framework for development
• Setting up the working rules of technology

Definition through experimentation

• Geometrical studies adapted to manufacturing
• Integrating material performance in the design
• Designing structural proposals
• Viability and case applications proposals

Demonstrating through synthesis

• Consolidated knowledge application

Large Scale Demonstrator Sample

SUMMARY OF PROGRESS

Schedule and timeline of the research

GEOMETRICAL PROBES

MULTICELL // PATH PLANNING

Planes:
Support planes: all flat
Corner planes diagonal: 22° flipped
Multiple planes: 0,3mm increase on height
Sequencing
Single cell strategies
Overal matrix
Linear vs zigzag

ROBOT/TOOL COLLISION

PathPlanning consideration on

• Printed cells
• Tool dimensions
• Tool rotations along 5º freedom

FRP LATTICE EXTRUDER

FRP 3D

Tool developped for geometrical testing

• Table size demonstrators
• WIP tool
• Path planning sequencing
• Methodology approach

FRP 3D

• Lattice generation capabilities
• Table size demonstrators
• Geometrical development tool
• Well stablished technology
• -1/10 scale models, depending on endeffector size

LARGE CFRP EXTRUDER

CFRP 3D

-Thermoplastic set with continuous fiber

• FDM with performance enhancement
• Constraints on robot equipment
• Proved technology

• Tools exist but they are not accessible
• Reduce the impact on access
• Provide access to tools

UV Extruder V1

UV Extruder V2

UV Pulltruder V2

• Continuous fiber 3d printing
• Laying deposition
• Co extrusion pull
• Tested extruder
• Nozzle die impregnation
• Fiber impregnation and pulling
• Rolling pressing device
• Set curing times to debug

UV Extruder V3

UV V3

On righ pulltruder tested

• Continuous fiber 3d printing
• Ommnidirectional
• Nozzle die impregnation

On left-iteration

• Co extrusion pull-extruder
• Bench tested
• Fiber impregnation pull and active extruder
• Two stages curing

RELEVANCE & SIGNIFICANCE OF STUDY

Speculation on the types of outcomes

Academic contributions

• Methodology for continuous fibre integration manufacturing processes in architecture structural elements and its possible applications.
• A design-fabrication methodology for composite construction without moulds, in order to reduce waste as result of fabrication processes, aiming to be suitable and easily integrated within the construction sector.
• A catalogue of artefacts as well an interpretation of current and in development AM techniques that could be applied among the construction industry.

Computational contributions

• Computational design protocols of geometrical implementation form-finding, based on the structural behaviour of geometric spatial lattice output models.
• A computational design protocol of multi-objective optimization for continuous fibre allocation in architectural elements and structures balancing out the mechanical, cost and design properties of the developed material processes.
• The capability of integrating high cost per weight material through a material optimization technique from a structural perspective, involving in the process the structural analysis by finite elements of sample models.

Industry contributions

• The Development of several ad hoc open-source extruders for continuous fibre 3d printing that allows multiple AM processes. Use of the so-called end effectors as a working prototype of affordable, open-source probing solutions.
• A catalogue of material implementation in these processes, indicating the qualitative and quantitative properties of these based on literature review and process testing through probes.

PROPOSED INDEX

Thesis chapter structure

• 1. State of the art
  1.1. Digital fabrication in constructions
  1.2. 3D printing technology
  1.2.1.Small scale-product oriented
  1.2.2.Large scale
  1.3. 3D printing in constructions
  1.4. Current fabrication technologies
  1.5. Technologies in development
  1.6. Methodologies & applications
  1.7. Structural performance and 3d printing
  1.8. Patents
  1.9. Conclusions
• 2. High performance in construction, frame of reference
  2.1. Implications of new materials approach at a construction level
  2.2. Automatization processes - Digitalization of the construction industry
  2.3. Feasibility & critical analysis of possible adoptions
  2.4. Adopted technologies, materials vs in adoption
  2.5. 3d printing opportunities
  2.6. Conclusions

• 3. Composite additive manufacturingmateriality in architecture
  3.1. Composite materials adoption in architecture
  3.2. Catalogue of performance and adequation
  3.3. Description and results
  3.4. Methodology for testing
  3.5. Fabrication adequation Onsite/offsite
  3.6. Conclusions
• 4.Fabrication
  4.1. Introduction Onsite/offsite
  4.2. Existing technologies
  4.3. A methodological approach based on material selection
  4.4. Characterization and design concerns associate with fabrications processes
  4.5. Tools development
  4.6. Workflow analysis and characterization
  4.7. Technologies limitations and possible best cases applicability

• 5. A computational geometric approach based on fabrication and material constraints
  5.1. Introduction
  5.2. DFM in architecture
  5.3. Integrative structural optimization design workflows for continuous fibre fabrication approaches
  5.4. Software capabilities and robotic arms integration
  5.5. Design approaches considerations
  5.6. Technical computational factors
  5.7. Native design suites to fabrication processes integrations
  5.8. Structural validation of models
  5.9. Material characterization and performance digital models
• 6. Design protocols
  6.1. Viability methodology
  6.2. Conclusions
  6.3. Multimaterial
  6.4. Implementation guidelines
  6.5. Structural performance comparison

• 7. Research Overview
  7.1. Adoption of technologies in construction industry possibilities
  7.2. Case study catalogue based on applications
• 8. Contextualized findings
  8.1. Structural performance-automatization of processes
  8.2. 3d printed Composites in architecture
  8.3. Economic impact
  8.4. Sustainability
• 9. Conclusions
  9.1. Conclusions
  9.2. Future work, space of improvement
• 10. Research overview
• 9. Bibliography
• 10. Appendix

BIBLIOGRAPHY

Geometry Articles/Research Papers

• Woods, B., Hill, I. and Friswell, M. (2016). Ultra-efficient wound composite truss
  structures. Composites Part A: Applied Science and Manufacturing, 90, pp.111-124.
• Solly, J., Früh, N., Saffarian, S., Aldinger, L., Margariti, G. and Knippers, J. (2019). Structural
  design of a lattice composite cantilever. Structures, 18, pp.28-40.
• Schwinn, T., La Magna, R., Reichert, S., Waimer, F., Knippers, J., Menges, A.: (2013),
  Prototyping Biomimetic Structures for Architecture, in Stacey, M. (Ed.), Prototyping Architecture: The Conference Papers, Building Centre Trust, London, 2013, pp 224-244. (ISBN 978-0-901919-17-5)
• Marin, Philippe & Philippe, Liveneau & Blanchi, Yann. (2012). Digital Materiality:
  Conception, fabrication, perception.
• Beorkrem, C. (2013) Material strategies in digital fabrication. Routledge, New York
• Soar, R. and Andreen, D. (2012). The Role of Additive Manufacturing and Physiomimetic
  Computational Design for Digital Construction. Architectural Design, 82(2), pp.126-135.
• Menges, A. (2012). Material Computation: Higher Integration in Morphogenetic Design.
  Architectural Design, 82(2), pp.14-21.
• Tam, Kam Ming Mark, Caitlin T. Mueller, James R. Coleman, and Nicholas W. Fine. 2016. “Stress Line Additive Manufacturing (SLAM) for 2.5-D Shells.” Journal of the International Association for Shell and Spatial Structures 57 (4): 249–59. https://doi.org/10.20898/j.iass.2016.190.856.

Material -Fabrication Articles/Research Papers

• Eichenhofer, Martin, Jesus I Maldonado, Florian Klunker, Paolo Ermanni, Composite Materials, fibre Composite Extrusion, Free Form Structures, and Thermoplastic Composites. 2015. “Analysis of Processing Conditions for a Novel 3D-.” 20th International Conference on Composite Materials, no. July: 19–24.
• Invernizzi, M., Natale, G., Levi, M., Turri, S. and Griffini, G. (2016). UV-Assisted 3D Printing of Glass and Carbon fibre-Reinforced Dual-Cure Polymer Composites. Materials, 9(7), p.583.
• ZOCCHI G.(2016), New Developments in 3D Printing of Composites: Photocurable Resins for
  UV-Assisted Processes, Department of Chemistry, Materials, and Chemical Engineering
• Moi Composites (2018) Continuous fibre Manufacturing (CFM) for 3D
  Printing.Moi Composites.Politecnico di Milano
• Gaikwad, Ajay & Kenjale, Akshay & Bhosale, Ajinkya & Dumbre, Tushar & Arakerimath,
  Rachayya & Roy, Sajal. (2015). Design Analysis & Manufacturing Of Carbon Composite
  Isotruss For Bending Analysis. IJEMR. 133-136.
• Omuro, Ryo, Masahito Ueda, Ryosuke Matsuzaki, Akira Todoroki, and Yoshiyasu Hirano. 2017. “Three-Dimensional Printing of Continuous Carbon fibre Reinforced Thermoplastics by in-Nozzle Impregnation with Compaction Roller.” ICCM International Conferences on Composite Materials 2017-Augus (August): 20–25.

Construction industry Articles/Research Papers

• Kroner, W. (1997). An intelligent and responsive architecture. Automation in Construction,6(5-6), pp.381-393
• Grosso Stegna,L.,Meinero,D., Volontà,M.,(2019) Reinventing construction through a
  productivity revolution. CECE
• MGI: Barbosa F., Woetzel J. , Mischke J. , Ribeirinho M.J., Sridhar M., Parsons M. ,Bertram N. , Brown S.(2017) MGI Reinventing Construction Full Report.
• Pan, Yifan, and Yulu Zhang. 2021. “3D Printing in Construction: State of the Art and Applications,” 1329–48.
  Analysis, Smart Tech. 2018. “3d Printed Composites Materials Markets.” https://www.smartechanalysis.com/reports/3d-printed-composites-materials-markets-2018/.

Design protocols Articles/Research Papers

• Hermann, C. (2004). Branko Kolarevic, ed.—Architecture in the Digital Age: Design and
  Manufacturing. Nexus Network Journal, 6(2), pp.131-134.
• Rusenova, G., Wittel, F., Aejmelaeus-Lindström, P., Gramazio, F. and Kohler, M. (2018). Load- Bearing Capacity and Deformation of Jammed Architectural Structures. 3D Printing and Additive Manufacturing, 5(4), pp.257-267.
• Hacka,N., Wanglerb,T., Mata-Falcónc,T., Dörflera,T., Kumard,N.,Nikolas Walzera,A., Grasere,K., Reiterb,L., Richnerb,H., Buchlid,J., Kaufmann,W., J. Flattb,R., Gramazioa,F., Kohler,M.(2017) , Mesh Mould: An On-Site, Robotically Fabricated, Functional Formwork. Chair of Architecture and Digital Fabrication, Department of Architecture, ETH Zurich
• Hack, N., Lauer, W.V.: Mesh-mould: robotically fabricated spatial meshes as reinforced
  concrete formwork. Archit. (2014)
• Braumann, J., Brell-Cokcan, S., (2015) Adaptive Robot Control New Parametric Workflows
  Directly from Design to KUKA Robots, University for Arts and Design Linz2Robots in
  Architecture | RWTH Aachen University
• Ginger Gardiner. (2020). 3D printing with continuous fibre: A landscape | CompositesWorld. CompositesWorld Magazine, (November), 24–26. Retrieved from https://www.compositesworld.com/articles/3d-printing-with-continuous-fibre-a-landscape