• Utilisation of ADDITIVE MANUFACTURING in post automatization and reducing cost on high complexity structure fabrication.
• CPM,FRP,AFP,CF3D composite material techniques for production of lightweight high strengh geometries.
• Material usage,optimization and enhancement of structures through SPATIAL FRAMES.

RESEARCH FRAMEWORK

The use of digital and robotic fabrication processes aims to investigate new possibilities for expanding the geometric complexity, functional integration, and a smart assembly logic
developing, new methodologies and processes that evolve and reinterpret the use of materials to produce an innovative architecture.

Additive manufacturing in Architecture

Is mainly deployed through layer-by-layer or contour crafting. **One of the first issues of fabrication at construction scale** is how to deposit bulk quantities of material (with a centimetre scale nozzle) keeping the buildingtime down, while resolving micron-scale details, required for the finish.

This being said, 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).

Implementation Goals

Several new material and fabrication technique investigations remain at exhibition scale as the cannot outperform already existing ones in relation to the combination of cost, on-site execution and construction.

• 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.

Keywords:

• Additive Fabrication
• Direct-deposition Fibre-Reinforced Composite (FRP)
• Construction Industry
• Robotic Fabrication
• Freeform geometries Performative Structures
• Spacial Structures

STATE OF THE ART

Existing research/projects in depth relevant to the thesis specific contribution

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**.

ICD, ITKE, TUM that explores on artificial fibre composites and biomimetic design principles.

ICD-ITKE

Continuous fiber winding

The use of continuous fiberglass and carbon composite enhances the structural properties to its maximum, geometrical design thought from the material improves the overall perfomance

Iridescence Print (2015) by Gramazio Kohler Research which research on the potential for the development of highly informed and geometrically complex architectural structures

High geometrical flexibility without constrains in the minimal cell size allowing custom geometrical gradients.Fabrication flexibility and repeateability without molds

MX3D-bridge (2018) by Joris Laarman Lab-Mx3d which demonstrates the use of performative materials on high stress structures

JorisLaarmanLab

Truss structures and space frames have long been the preferred solutions to the problem of maximizing structural efficiency, as they allow to multiply in the flexural rigidity and load-bearing capacity achievable from a given amount of material (Woods, 2017).

BRANCH TECHNOLOGY

Spatial framing FRP

Double compositive manufacturing from the microscale(material space frames) to the final object(wall) using multiple materials used at its best to outperfoms similar formfactor systems

Structural optimization at micro/macrolevel

The use of fibre composites with its strong bond between the matrix and the fibres allows designing functionally graded geometries on a cell scale matching the geometrical differenciation between the general structural parts.

MOI COMPOSITES

UV instant curing deposition

Continous fiber deposition without any formwork allos to deposit the fiber in the best performative position whilst following the geometrical shape to fabricate.Allow customize reinforcements on the main manufacturing process

High homogenous fiber bond on a microscale eliminating the traditional problem of bidimensional additive manufacturing of non uniform structural properties.

SCIENTIFIC INTEREST

Specific contribution in relation to the body of research that exists

The scientific interest of this research is to keep a parallel approach to fabrication, material and the morphological formation of spatial frames adapted to composites manufacturing technologies and its further application in construction.

This investigation aims to demonstrate the possible applications and future deploy of this systems in the construction industry.

3D printing should be used for what it does best,(M.Tonizzo 2013) which includes optimizing workflows. Conventional methods of additive manufacturing have been affected both by gravity and printing environment: the creation of 3D objects on irregular, or non-horizontal surfaces has so far been treated as impossible. 

• CPM offers fabrication without moulds or tooling.
• Offers multifunctional structures.
• Opens the door to a world of hybridized manufacturing

The research proposes an update of the previously done research of material-fabrication informed composites structures , structurally informed geometry systems and its application for architectural construction techniques as well as investigation on fabrication methodologies. Furthermore, this investigation aims to demonstrate and the ability of application and future deploy of this system in the construction industry.

Applications of High structural or lightweights structures needs, multi-step assembly construction processes where fast deployability is a need and functionally graded elements that outperforms on-site custom fabrication cutting down on constructions times could benefit from the impact of this research.

RESEARCH HYPOTHESIS/STATEMENT

Problematic to face through the thesis

An application of FRP in architecture poses the inherent problem that either requires moulds or the use of layer by layer deposition techniques. That manufacturing process implies a large material demand for producing lightweight parts and time-intensive fabrication procedures to produce those temporal body frames.

Being able to improve the materiality of this process would likely be able to perform an **additive-winding methodology that is free from the use of a base frame**, making it possible to create spatial wireframes on any given working surface, Surface, independent from its inclination and pattern entanglement.

Fabrication technology of these characteristics will help manufacture large structures whilst keeping the geometrical complexity yielding to new architectural opportunities with the possibilities to generate functionally graded materials on a macro-level that adapts the geometrical and structural needs of architecture.

RESEARCH AIMS & OBJECTIVES

PRIMARY GOALS

• Clasification by structural design point of view of specific non-standard geometries spatial frame formation for saving material of load-bearing structures.
• Categorization of material systems able to outperform traditionally used architectural materials.
• To explore and categorise the fabrication technology for the absence of moulds
• Define the geometrical design and structural performance parameters on space frame design
• Materiality research on fast curing deployable 3d printing composites
• The digitalization of composite parts behaviour by spatial structural frame algorithms
• Material/utilization/deployment cost differentation on architecture construction industry

SECONDARY GOALS

• Feasibility study on the implementation of functionally graded structures in to the space frame system to enhance the material usage optimization being much more efficient on supported load/self-weight ratios.
• Design process algorithms creation for automatic production of a wide catalogue of space frame typologies.
• Implementation of these fabrication strategies from a direct structural application to possible use as performative formwork for jammed architectural structures or leaking formwork.
• Ultra-lightweight thin section encapsulating lost formwork.
• To define the possibility to realize internal, structurally gradient porosity cores during the 3D printing process with no discontinuity
• To investigate and define the geometrical design and structural performance parameters for further possible applications
• Material analisis - impact on cost/benefit of additive manufacturing techniques studied regarding construction implementation.

RESEARCH METHODOLOGY

How to emphasise these aims

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

• Material combination samples studies and test to produce high perfomance composites materials.
• A series of 3D printing material tests will be done to fortify the fabrication process
• Composites plastic/thermoresin and uvresin 3D printing endeffectors will be developed for association with robotic arm.
• Continous dry and wet fiber impregnation in-situ deposition

• Anisotropic vs isotropic fiber directional and density samples testing
• Spacial frame geometry generation algorithms development to self adapt based on inputs shapes
• Algorithm automatization for manufactoring logic developments bottom up approach.
• Design parameters and logics will be computationally developed and than applied to the
  fabrication process.

• Manufacturing procedural assembly comparative of the different material implementation. Cost-time-perfomance-flexiblity analisis
• Samples prototypes batch production to analise on bench test on structural properties to stablish perfomative values.
• 1:1 Probe execution showcasing the integrity of the structural system focussing on the control and documentation of the fabrication procedure. In order to stablish weakness and strong points of the process, to streamline production techniques.

GANTT CHART

Working program of development

W.I.P

EXPECTED RESULTS

Speculation on the types of outcomes

• Expected Result 1: Directly correlation of continous fiber material implementation to individual additive manufacturing techniques

• Expected Result 2: Guidelines of implementation of material/manufacturing sytems adapted to structural needs

• Expected Result 3: Development of fabrication tools to allow the implementation of this material systems (endeffectors)

• Expected Result 4: Development of computational tools (plugin) for automatization the space frame manufacturing process

• Expected Result 5: Material implementation conclusion - impact on cost benefit of individuals additive manufacturing regarding FRP

• Expected Result 6: Probe demonstrators of the different systems as test models

INITIAL INDEX

• 0. Introduction

  • State of the art
  • Research framework
  • Research objectives
  • Research Methodology
  • Initial literature

• 1. Study of high perfomance 3d printable materials

  • 1.1 Classification by performance
  • 1.2 Study on manufacturing typology Implementation
  • 1.3 Test and essays on feseability.

• 2. Space frames

  • 2.1 Geometry formation
  • 2.2 Structural behaviour analisis
  • 2.3 Procedural formation
  • 2.4 Discussion of the best typologies to be implemented for CFAM
  • 2.5 Digital models to be compared to test probes

• 3. Fabrication methodologies

  • 3.1 Characterization of fabrication by Materiality
  • 3.2 Characterization by materiality implementation
  • 3.3 Cost/benefit/feasiblity study for industry

• 4. Architectural elements
  • 4.1 Definition of architectural implementation based on traditional construction elements
  • 4.2 Study of new posibilities upcoming of this methodology
  • 4.3 Fabrication of scale prototypes on several techniques and Materials
  • 4.4 Samples test and essays to be perfomed
  • 4.5 Catalog of posible architectural geometries

• 5. Implementation
  • 5.1 Optimized geometrical adapted models
  • 5.2 Stablishment of protocols
  • 5.3 Geometrical rules conformation
  • 5.4 Protocols for fabrication
  • 5.5 Digital to real model structural deviations

• 6. Research Overview
  • 6.1 Holistic guidelines
  • 6.2 Implementation accuracy
• 7. Conclusions
• 8. Further research
• 9. Bibliography
• 10. Appendix

INITIAL BIBLIOGRAPHY

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• 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 ControlNew Parametric Workflows Directly from Design to KUKA Robots,University for Arts and Design Linz2Robots in Architecture | RWTH Aachen University
• 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.
• 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.
• 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)

• Invernizzi, M., Natale, G., Levi, M., Turri, S. and Griffini, G. (2016). UV-Assisted 3D Printing of Glass and Carbon Fiber-Reinforced Dual-Cure Polymer Composites. Materials, 9(7), p.583.
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• Marin, Philippe & Philippe, Liveneau & Blanchi, Yann. (2012). Digital Materiality: Conception, fabrication, perception.
• Bonwetsch, T., Gramazio, F., & Kohler, M. (2007). Digitally Fabricating Non-Standardised Brick Wall. Proceedings from ManuBuild, Rotterdam.
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• Moi Composites (2018) Continuous Fiber Manufacturing (CFM) for 3D Printing.MoiComposites.Politecnico di Milano
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• Kroner, W. (1997). An intelligent and responsive architecture. Automation in Construction, 6(5-6), pp.381-393.
• Hermann, C. (2004). Branko Kolarevic, ed.—Architecture in the Digital Age: Design and Manufacturing. Nexus Network Journal, 6(2), pp.131-134.
• 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.
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