Design and System Considerations for Construction-Scale Concrete Additive Manufacturing in Remote Environments via Robotic Arm Deposition

Abstract

This work explores additive manufacturing (AM) of concrete by using a six-axis robotic arm and its use in large-scale, autonomous concrete construction. Concrete AM uses an extrusion method to deposit concrete beads in layers to create a three-dimensional (3D) shape. This method has been found to have many uses and advantages in construction applications. The lack of formwork and autonomous nature of this manufacturing method allows for new geometries and materials to be printed in unsafe or challenging environments. Autonomous construction has been suggested as a method of creating habitats in rapid-response scenarios. This article discusses research toward one such system that could be used to rapidly construct necessary habitats in response to low-resource and emergency situations. This required addressing certain limitations of a six-axis robotic arm platform along with overcoming system challenges to achieve deliverables for NASA's ''3D Printed Habitat Challenge.'' This included system design to increase the build volume, integrate embedding, print non-coplanar sections, and minimize travel moves to address the challenges associated with continuous extrusion of cementitious material. The system was demonstrated by printing a one-third scale habitat, which represents the first 3d-printed fully enclosed structure at an architectural scale without the use of support.

Advanced manufacturing and digital twin technology for nuclear energy*

“…In advanced manufacturing, robots are commonly used for tasks such as welding, printing, cutting, material handling, assembly, and inspection (Ding et al, 2015a;Djuric et al, 2016). They can operate in hazardous or challenging environments, reducing the risk to human operators (Meisel et al, 2022). In the nuclear industry, robots play a crucial role in handling hazardous or radioactive materials, performing maintenance tasks in radioactive environments, and supporting decommissioning activities (Sundar et al, 2012;Tsitsimpelis et al, 2019).…”

An Overview of Smart Materials and Technologies for Concrete Construction in Cold Weather

“…The use of robotic systems in the construction industry can help improve efficiency, reduce labor costs, and enhance quality and performance [218]. Robotic systems can be used for a range of construction tasks, such as concrete placement [219], reinforcement installation [220], and formwork assembly [221], helping to streamline construction processes and ensure consistent quality and performance.…”

A review of concrete 3D printed structural members

“…The development of the system required improvements in the system's movement, localization, and motion control for proper deposition. Meisel et al (2022) demonstrated a system for printing fully enclosed structures without much external support. The potential to use such a system in the intra-planetary civilization is explored, but it needed improvements in printing complex geometries.…”