Automated Additive Manufacturing of Concrete Structures without Formwork - Concept for Path Planning

Ibrahim, Serhat; Olbrich, Alexander; Lindemann, Hans; Gerbers, Roman; Kloft, Harald; Dröder, Klaus; Raatz, Annika

doi:10.1007/978-3-662-56714-2_10

Cited by 10 publications

(5 citation statements)

References 4 publications

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“…The printed layer for extrusion based 3D printing as well as for the SC3DP process can be approximated with a rectangle defined by a layer height L h and layer width L w [10]. The cross section is then represented by a quasi 2D mesh of points as shown in Fig 1a . Each point in the 2D mesh represents a node with i,j,k coordinates in the local coordinate system.…”

Section: Generation Of Mesh Geometry From Printing Trajectorymentioning

confidence: 99%

Implementation of a surrogate model for a novel path‐based finite element simulation for additive manufacturing processes in construction

Ekanayaka

Hürkamp

2023

Proc Appl Math and Mech

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Additive manufacturing in large-scale construction is an ongoing research topic that shows significant potential to overcome the challenges in terms of efficient material usage and process automation in construction. A large challenge in deposition based additive manufacturing processes of concrete material is to ensure the structural stability while printing. Due to the weak material properties of the fresh concrete, it has to be ensured that during the printing process the not fully cured printed structure is able to carry its own weight. This requires process stabilization and a proper process control to prevent a collapse of the structure. Therefore, a numerical model of the printing process that takes into account the time dependent material behavior of the applied concrete as well as the printing path and the process parameters is necessary to support the process planning. Within the framework of project B04 of the collaborative research center TRR277 -Additive Manufacturing in Construction, a novel path-based finite element simulation was developed in which the simulated geometry is constructed directly from the printing trajectory. Additionally, this approach allows the time-dependent material properties of fresh concrete to be modeled directly and efficiently into the mesh of the printed structure. Since the computation of large scale printing processes with finite element simulations is quite expensive, there exists a need for a much faster computational model. In this contribution, the implementation of a surrogate model based on a neural network and its deployment to optimize the interlayer waiting time is presented.

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Section: Generation Of Mesh Geometry From Printing Trajectorymentioning

confidence: 99%

Implementation of a surrogate model for a novel path‐based finite element simulation for additive manufacturing processes in construction

Ekanayaka

Hürkamp

2023

Proc Appl Math and Mech

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“…According to experimental observations of SC3DP in ref. [8], the relation between process parameters and strand geometry is given by…”

Section: Process Based Finite Element Analysis For Ammentioning

confidence: 99%

“…According to experimental observations of SC3DP in ref. [8], the relation between process parameters and strand geometry is given by

\begin{equation} L_h = \dfrac{Q_c}{v_n \cdot L_w} \quad \text{and} \qquad L_w = m\cdot d_n + b \text{,} \end{equation}

where

v_n

denotes the nozzle velocity,

{Q}_c

denotes the volume flow of concrete and

d_n

the nozzle distance. The parameters m and b are fitting parameters determined from experiments describing the liner relation between layer width and nozzle distance.…”

Section: Process Based Finite Element Analysis For Ammentioning

confidence: 99%

A novel surrogate modelling approach for additive manufacturing processes

Hürkamp,

Ekanayaka

2023

Proc Appl Math and Mech

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Additive manufacturing (AM) enables the production of complex and customised components with minimal waste. However, to achieve the desired geometry and quality, a lot of process optimisation is needed (often by experimental trial and error). Especially, in the case of AM with concrete materials, the time‐dependent behaviour of the fresh concrete is a large challenge to achieve process stability. Simulations taking into account the time‐dependent material are able to predict the printing result. Since these simulations are very time consuming, a proper orthogonal decomposition (POD)‐based reduced order model for AM is presented. Based on snapshots along the build‐up process, a surrogate model is constructed that is able to predict the printing result with respect to the underlying process and materials. Inspired by the POD approximation, a novel surrogate modelling approach using the initial waypoints of the printing trajectory as input is investigated. In this case, it is possible to analyse the manufacturing process for arbitrary geometries. The proposed method is demonstrated for the use case of additive manufacturing in construction.

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“…In order to subsequently guarantee a consistent component quality during production, the resulting simulation models must be optimized with regard to their computing time and transferred into path planning and control concepts (project B04, Figure 9D). 27 Advances in robotics and the latest optimisation methods make it possible to explore these control loops for robots with an extended degree of freedom and thus to operate with coordinated motion sequences with high precision in enlarged installation spaces, in favor of the realization possibilities of individualized and large‐scale products 28 . The transfer of the developed concepts to mobile robots further provides the possibility for flexible on‐site production without restrictions regarding the available working space (project B05, Figure 9E).…”

Section: Presentation Of the Focus Areas Of The Trr 277 (Focus Areas A B And C)mentioning

confidence: 99%

TRR 277: Additive manufacturing in construction

Kloft

Gehlen

Dörfler

et al. 2021

Civil Engineering Design

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The building industry is one of the least digitalized sectors of the global economy to date. Unlike other industrial sectors, the manufacturing of buildings is characterized by traditional handicraft techniques and individualized construction processes. Digital production technologies from other industrial sectors have not become established in the construction industry because they do not allow the necessary individualization or are uneconomical to transfer to construction. The advantages of additive manufacturing (AM) technologies are that automation and individualization are not contradictory. Furthermore, a new design strategy is embedded in 3D printing, namely to build up material only where it is structurally or functionally needed. AM is, therefore, both economical and resource‐efficient. The DFG Collaborative Research Centre/Transregio TRR 277 Additive Manufacturing in Construction (AMC) of the two universities TU Braunschweig and TU Munich wants to research the technology of AM fundamentally and also contributes to the digitization of the construction industry. This article gives an overview of the goals, work programme, and methods of the TRR 277, as well as its three focus areas and 18 scientific research projects.

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Automated Additive Manufacturing of Concrete Structures without Formwork - Concept for Path Planning

Cited by 10 publications

References 4 publications

Implementation of a surrogate model for a novel path‐based finite element simulation for additive manufacturing processes in construction

Implementation of a surrogate model for a novel path‐based finite element simulation for additive manufacturing processes in construction

A novel surrogate modelling approach for additive manufacturing processes

TRR 277: Additive manufacturing in construction

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