3D printing in construction group report IFN 502 group assignemnt

0 Group report for IFN502 Group Assignment

2015

Jessica Pinto n9522778

Sanjana Farhin n9543457

Sneha Shiggaon n9520554

Tutor: Ms. Mindy Nagra

Queensland University of technology

11/8/2015

The analysis of introducing 3D printing into Construction

The analysis of introducing 3D printing into Construction November 8, 2015

Contents

Introduction .................................................................................................................... 2

Key features of the technology .................................................................................. 2

Statement of context..................................................................................................... 3

Key benefits of 3D printing in construction industry ....................................... 3

Key issues associated with implementing or exploiting 3D printing in

construction sector ....................................................................................................... 4

Lessons gained from applying below theories to the introduction of 3D

printing into construction .......................................................................................... 5

Theory: Transaction Cost theory ................................................................................... 5

Theory: Socio Technical theory ..................................................................................... 5

Theory: Disruptive innovation ....................................................................................... 6

Recommendation .......................................................................................................... 6

Summary and Conclusion .......................................................................................... 7


Introduction

1 The next industrial revolution is all about personal fabrication in

manufacturing industry, and it’s happening now. With 3D printing we can create,

innovate and fabricate things and is all set to change the world. 3D printing is an

emerging technology growing rapidly from past a decade. In this report we attempt

to give an introduction to 3D printing and briefly discuss about its key features,

benefits and issues that are possible while implementing this technology in the

construction industry.

Key features of the technology

2.1 3D (three dimensional) printing is a part of process known as additive manufacturing where object is created by adding material layer by layer. Additive manufacturing is a process of making a physical object from a three dimensional digital model, by laying down successive thin layers of material such as glass, plastic, metal, even human cells. These materials can come in a form of powder, liquids, filaments or sheets. These material can be incorporated by several means such as spraying, extruding or setting them with a laser beam. 3D printers differ from one another by their usage but the basic configuration of all printer remain the same as below as per figure 1.1

1 Figure 1 How 3D printing works

2.2 Key features of the technology: 1 Grynol, B. (2015)


Speed - the speed of the printer differs from one another the range of speed is about 40 mm/s to max 100mm/s

Extruders- the thickness of each layer depends on the extruder which is a machine that pushes the base material out.

Usage of special modelling software - 3D printer create an animated print imitation by using 3D modelling software.

Durable- can be used on a daily basis and requires less maintenance.

Accurate results while balancing resolution and speed.

Large build areas on which the product is built.

Statement of context 3.1 Construction is a process of building, renovating or knocking down of an infrastructure such as roads, railway, buildings and transmission lines. While majority of work is focussed on constructing new structures, the rest are involved in altering or extending operative buildings. The different areas of activity are engineering construction, non-residential building and residential building.

3.2 Demand for construction projects depends on certain factors such as population and income growth, commodity cycles, consumer opinion, interest rates and inflation.2The rate and availability of skilled labour, building materials and equipment determine the growth pace of the industry. This industry is continuously changing and being transformed in order to meet the demands of the present generation. The basic methods have encountered several advancements but the technological modification have had a greater impact, from management methods and materials to innovations. If the construction sector is inefficient it will be difficult for a city to acquire substantial development. 3.3 Soon after 3D printing was invented, researchers initiated the use of it in this sector to build construction elements.3 This is known as Additive Manufacturing which is the sequential layering of very different materials such as concrete. It can be used to create big and small complex components and also print an entire building. It allows printing and creation to be fast and accurate however reducing labour costs and generating less waste. Furthermore, it enables construction in dangerous and bleak environments.

3.4 3D printing can bring about a great sense of competitiveness in the industry. The advantage arises from its broad area of uses. Not only does it print quickly, but also allows to envision a project clearly serving to reduce errors during construction. Above all, it bridges the gap between designers and engineers who bring the design to life.

Key benefits of 3D printing in construction industry

2 Toth, Freebairn, & Hu R. (2015) 3 McGee & Ponce de Leon (2014)


4.1 Cutting edge technology is under development and research since 2004 to

flexibly construct buildings, with built in facilities of plumbing and electricity using

the new technology of 3D printers. U.S president Barack Obama called this

technology as a future of manufacturing industry.4 This report gives brief explanation

on how 3Dprinting is going to revolutionise the construction industry in the coming

decades with the use of additive manufacturing process.

4.2 The key benefits identified working with 3D printing technology are as below:

Custom manufacturing – Provides design flexibility in terms of

customization with structure, construction material and design of customer’s

choice. Since with 3D printing construction with any material and shape is

easy to build. Building complex structures is more idealistic and practical

possibility with this technology

Low cost and time of construction – In construction industry the three

common factors of cost are material, labour and time cost. By using 3D

printing these costs can be minimal and can reduce the cost of construction

drastically. Win sun, Chinese printing company expects to save 50% on the

cost of building a house.5

o Reduced raw material cost -

o Reduced labour cost - minimal human effort is required for

construction after using this technology hence eventually reduces the

labour cost.

o Faster and accurate construction -

o Reduced energy consumptions – The 3D printing using additive

manufacturing process reduces up to 70% of energy consumption

overall compared the traditional way of construction.6

Environmental friendly – produces less waste compared to traditional

method, and printed materials can be recycled if not used at that time. The

recycled material can be used for construction.

4.3 Along with the above advantages 3D printing has a disruptive potential. 3D

printing enables prototyping in construction by architects to check for accuracy and

errors. The most disruptive innovation of 3D printing is the ability to build

disposable house. That is house built in less than a day and easily disposable as well.

Key issues associated with implementing or exploiting 3D

printing in construction sector

5.1 3D printing has an enormous potential in this sector however there are a few pitfalls that cannot ignored. It is a costly affair and unsuited for large scale production. Despite that their political and social impacts haven’t yet been fully

4 CBS News (2013) 5 Burger, n.d. 6 Tamarajan (2012)


discovered. These need to be addressed before implementing it as a profitable solution. The following have been identified as the key issues:

5.2 Since the printer would be performing the main task of constructing, it will drastically decline the employee numbers thereby disrupting the labour community. Traditional manufacturing and product companies could suffer as they will no longer have business which will eventually lead to loss of jobs. 5.3 Transportation of the printer to and from the site would be a hassle. If transporting is a success, the problem of storing in situ becomes an issue. Any errors in the digital model during designing and constructing phase could result in additional time on site, if the components are created on the spot. 5.4 Raw materials used will be limited as the same printer may not be accommodative to different materials.

5.5 Replicating architecture and patented designs off the internet will be a violation of copyrights. This is regarded as a crime.

5.6 The greatest challenge is educating design engineers about the flexibility brought by this technology. Intensive training and education needs to be provided. Change is difficult but it fosters innovation and imagination.

5.7 If 3D printers become commercial it won’t be long before every household owns one! The possibility of custom designing every little item would be limitless. The companies providing these printers and the constructing sector will suffer and eventually they will disappear one day too.

Lessons gained from applying below theories to the

introduction of 3D printing into construction

Theory: Transaction Cost theory Transaction cost theory is the total cost incurred during the process. For

construction using 3D printing the cost incurred will be maximum for the 3D

printer hence it’s not ideal for a construction company to buy a printer to

build 1 or 2 buildings since printers are very expensive such companies can

rent out a printer. Hence a company with large number of construction

contracts would be ideal to buy a printer on its own. By incorporating the

theory of transaction cost in this technology will minimise the construction

cost and save almost one fifth of the construction time hence increases the

profit of the firm.

Theory: Socio Technical theory The term Socio Technical theory takes after the objective of coordinating the

social necessities of individuals taking every necessary step with the specialized

prerequisites expected to keep the work frameworks doable as to their surroundings

of 3D printing in construction industry. While this innovation has been created to

make better approaches for working and expand wellbeing amid development, it may


baffle built up organizations, damage efficiency and fulfilment. Thusly a socio-

technical framework (STS) gives a comprehension of how a worker co-works and

uses this innovation to complete their work. It demonstrates to us how the viable

reality of functioning realizes the objectives of the association.

Theory: Disruptive innovation Disruptive innovation is an innovation that creates a new market over an

existing market by disrupting the value of the existing market. The study states that

not all inventions are disruptive even if they revolutionise the industry. 3D printing is

set to change the development business by finding distinctive methods for building

houses quicker and conservative, for example, building house with plastic, or

reusable development waste. 3D printing is disrupting the development market with

the additive manufacturing systems. The 3D printing empowers structures outfitted

with pipes and electrical lines while printing the house. The use of 3D printing would

definitely impact the construction workers and their employability but with that

innovation in 3D printing would increase the employment in development and

research of 3D printers in mere future.

Recommendation

7.1 Strongly recommend to adopt 3D printing technology for construction industry since it is very eco-friendly method of constructing and economical as well as faster than the traditional method. It can provide relief to those who’ve lost their homes in disaster zones. Projects can be completed within few days so time will play a major role in competition. 7.2 The application area of the discussed technology could also be Architecture firms. Until recent years’ models were built by hand, often taking a long time. Thus, architects are often forced to show their clients drawings of their projects. Now by using 3D modelling software architects or architecture firm can generate prototype model to show their clients what would be the final product, in a small amount of time. Using 3D printing, these firms can reduce times of production by 50 to 80 percent,7 producing scale models up to 60 percent lighter than the machined part without compromising strength.8 7.3 As for a company that hasn’t yet implemented the technology, we suggest to wait a few more years as full-fledged research and understanding of this technology is required. Companies will need to determine how these technologies will change the industry and what legal issues will need to be consider in order for them to be utilized. Before incorporating these manufacturing methods CEO of the firm should consider how the technology changes their exposure to risk and should consult with knowledgeable professionals. But when implemented, the main focus should be shifted from the technical benefits to how the printer is enabling innovation and creating value. Adopting to 3D printing affects multiple areas and not just architecture and design. Implementing the technology will not be without its challenges. Training, return on investments, cost effective customization and productivity are some of the main factors to be kept in mind.

7 Knippers E. (2015) 8 Stratasys (2015)


Summary and Conclusion

8.1 This report gives an overview on how disruptive and cost effective the 3D

printing is in construction industry. It also has socio technical significance for

people, organisation and society. This technology also called additive manufacturing

process, transforms traditional construction method due to its key features such as

accuracy, durability, environment friendly and construction speed.

8.2 With 3D printing people can now live in their dream house by paying less and

they need not wait for years to build it. Its eco-friendly since it produces less waste

and the raw material used can be recycled and reused. Hence reduces material cost

and increases re-usability.

8.3 3D printers differ from one another by their usage but the basic configuration

of all printer remains the same. The cost of 3D printers is high and is ideal for the

companies with big projects to buy one. Hence it is recommended that smaller

companies rent the 3D printers instead of buying a new one.

8.4 In conclusion, 3D printing will change how the world sees construction

industry. Taking everything into account, 3D printing may dramatically affect the

world. The suggestions for the residential side of life are more restorative concerning

more choices for customisable kitchen sets, the odd telephone case here and there

and perhaps a decent keychain, however the genuine side of the contention is the

business end.9

9 Hu R. (2012)


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Appendix 1: Individual report 1

Key features of the technology More than any other field, technology has affected human history the most such as

the World Wide Web, aeroplanes and even a simple bulb. These technologies paved

the way for new opportunities and possibilities. But it takes time for the disruptive

nature of it to become alleged. 3D printing is one of those technologies.10

3D printing is part of a process called Additive Manufacturing where in a computer-

controlled subsequent layering of materials is used to create a 3 dimensional shape.

It is peculiarly useful for prototyping and for manufacturing geometrically complex

objects at a reduced cost and time. This will open up new opportunities for mass

10 3d Pritning Industry (2014)


customization. Mass customization deals with changing the product or service to

satisfy a given consumer group.11 It also changes a consumer from being passive to an

active creator. All the objects created are protected by copy write.

Key features of the technology:

Large build areas on which the product is built.

Extruders- the thickness of each layer depends on the extruder which is a machine that pushes the base material out.

It includes a software to model the desired product.

Print speed- rate at which the extruder moves defines the printer speed.

Durable- can be used on a daily basis and requires less maintenance.

Accurate results while balancing resolution and speed.

Statement of context The construction industry comprises of work involved with the construction,

alteration or demolition of buildings and structures of sites. Construction is one of

the alarming occupations in the world where falls are inevitable causing terrible

injuries whilst displaying a high level of competitiveness. Supports such as

guardrails, ladders and staging a scaffold are some of the safety equipment that can

curtail risks but is still an ugly affair. Safe Work Australia Statistics show that 129

Australians have been killed at work as of mid-2014.12 The Australian Strategy has

identified the construction industry as a priority for work health and safety.13

Introducing 3D printing technology will not only reduce causalities but also be

environmentally friendly and cost effective. This process saves between 30%-60%

construction waste and slashes production time and labour costs by 50%-70% and

50-80% respectively.14 3D printing research continues to ramp up encouraging

opportunities for this industry to become greener and more cost effective.

Key benefits of the 3D printing in the construction industry The process of designing objects from a digital model is going to be very popular. U.S

president Barack Obama called it the future of manufacturing.15 3D printers can

produce almost anything including themselves. The more it develops the more a

construction process will revolutionize. “Would they like to live in a house that came

from a printer? Would they prefer concrete or plastic?” are the questions being faced

by residential construction companies.

The essential benefits identified working with this technology are:

11 Martin (2015) 12 Keane (2014) 13 Safe Work Australia, n.d. 14Starr (2015) 15 CBS News (2013)


Customisation and clearer client expectations- permits customization based on the

needs of a customer.

Improved Project Planning- the essential part of a project is the design. With 3D

printing, companies will be able to quickly and inexpensively create models for visual

representation as well as avoid delays and defects.

Environment friendly- creates lighter and stronger design that imposes a carbon

footprint compared with traditionally manufactured products.16 Also since the use of

lumber will be greatly reduced there will be great advancements for ‘green’

construction firms.

Reduced supply costs- WinSun, a Chinese 3D printing company expects to save up to

50% on the cost of building a house.17

Along with these common advantages, people will get their dream houses in

less time and high speed. The overall energy consumption will decrease. Furthermore

companies will be profited as they can handle many projects simultaneously and hard

labor will reduce.

Is 3D printing disruptive or not? Many things from toys to building parts are

being made on a daily basis. It changes the orderly fashion in which manufacturing

takes place. The initial potential market was quite small because it was used to just

make simple drafts. Despite that, new uses are continually arising. In the future,

factors such as extra speed, precision and capacity are being added to the printer in

order to make precise complex objects. The ability to fast fashion every building and

construction item could bring new start-up companies who are all about the speed and

flexibility without holding stockpile. It may also frustrate established companies,

sabotage productivity and satisfaction. Time-to-market would be reduced drastically

which would make time itself the new important factor for competition.

It could also put a restraint on outsourced manufacturing to countries. There

won’t be a demand for labor force. Also since it has the ability to disrupt global

manufacturing, it may lead to shocks in employment, consumption and production.18

3D printing will surely lead to value creation.

3D printing becomes disruptive when affected businesses refuse to accept

their business model is ancient. Moving towards trends or places where 3D printing

hasn’t reached is the only way present businesses can last. Being innovative is a

counter measure of being disruptive.

After outlining the core benefits in construction, it is highly advisable to

implement 3D printing. By implementing this technology, the following results can

be achieved: product flexibility, improved spare part management, reducing design

and demo product investments.

16 3D printing industry (2014) 17 Burger, n.d. (2012) 18 Tesla C. (2014)


Key issues The 3D printer is a double-edged sword. It stands to transform technology and

society for the better but we also can’t ignore the potential negative consequences.19

For so many years, this industry has been using cement. It is very complex and if one

portion of ingredient is changed then the entire batch goes to waste. Knowledge of its

behaviour depends on trial and error. Hence it might be hard to adapt to 3D printing.

It will take many years of experiments to decide the right combination of hardware

and cement material to get started with the printer. Also the different concrete layers

bonded together, dry at different rates so there is a high chance of it fracturing.

It is also a costly affair and unsuited for large scale products. But their social,

political and economic impacts are yet to be fully discovered.

The following have been identified as key issues in implementing this

technology in the construction sector:

Supply chain decline- supply chains and shipping of goods will be impacted.

Shipping impacts things like tariffs, international trade, retail outlets.

Labor decline- traditional construction industries will be hit badly as people

make their own products. Thus effecting product transportation costs. This in turn

will lead to massive decline in jobs.

Privacy/Intellectual property protection- for construction of houses, the choice

of design lies in the hands of the customer. Derivatives of patented designs and

architecture can be reproduced.

Labor force experience and organizational readiness- lot of technical knowledge

needs to be developed before it can be implemented

Houses from a printer may not have a deep strong foundation. The materials

used are limited and houses made of plastic may compress or expand due to climatic

changes. Also the lack of expertise, formal standards and proven documentation of

its capabilities show that it hasn’t grown to its fullest. Moreover, there are high

chances of people not staying in a house that came from a printer!

The long term outlook is promising but there are risks in diving into such a

huge commitment. 3D-printed buildings raise legitimate issues and there are post-

construction dispute risks.

Firstly, to overcome these issues, stronger materials should be used to build

these houses which are also climate independent. At least for the construction of

taller buildings, traditional methods should be used until 3D printing is fully

developed. It is in a prime stage for manufacturing smaller objects. It will be long

before the public starts accepting this new technology. Looking at these negative

aspects of the tech, it is recommended to wait for a couple of years till 3D printing

reaches a mature and stable state.

19 Gilpin L. (2014)


Lessons gained from applying Socio Technical theory to 3D printing into construction The term Socio Technical theory follows the goal of integrating the social

requirements (known as the elder systems) of people doing the work with the

technical requirements needed to keep the work systems feasible with regard to their

environments.20 If people led technology there are chances it could go wrong but if

technology led people, it definitely will go wrong! To see 3D printing as just a

technology is underestimating it. Tech has to merge with people not vice versa.

With the uncontrollable growth of devices, technologies have become the

principal tool in our daily routine. While 3D printing is expected to have a massive

blow on society and culture, there are still many challenges. Up to now most

attempts are made to discover the development and integration of this technology.

Lesser efforts are being made to notice the impact of the organizational changes and

user issues built-in in expanding 3D printing. This is critical to understand its

success and for it to stay. Both systems must work effectively. The working

conditions and organizational infrastructure need to function together to perform

better.

The rise of 3D printing has socio technical significance for people, organizations

and societies. While this technology has been developed to make new ways of

working and increase safety during construction, it may frustrate established

companies, sabotage productivity and satisfaction. Therefore a socio-technical

system (STS) provides an understanding of how an employee co-operates and uses

this technology to get their work done. It shows us how the practical reality of

working brings about the goals of the organisation.

To be an effective technology, it should be sustainable, provide interoperability

and aid collaboration. There might be instances where 3D printing might not be

embedded into the daily work routine and workers have an option whether or not to

use it. Most of the time new systems don’t get used or just a part is explored. A main

goal of the STS approach is to create a flexible work system that is readily adaptable

to the disturbance of the outside world. And the only way an organisation will work

successfully is if the people adapt to this technology successfully.

The group of people responsible for bringing an organisational change usually

have extensive knowledge on business management and business processes whereas

the systems development group have strong technical knowledge. So by bringing a

change it may have an impact on other parts of the business. Hence it is important

that the demands of the social, technical and organisational systems are taken into

account to synchronise their activities.

To overcome such challenges, emphasis should be made on the overall business

value, involvement of its employees and impact on society. Instead of finding

products that fit the printer, efforts should be made to make the printer fit the

product.21

20 Fox W. (1995) 21 Stratasys direct (2015)


Summary and Recommendations The aim of this report was to show the key features of 3D printing in the

construction industry. The key benefits and issues in implementing 3D printing in

construction were investigated and outlined. The use of a socio-technical framework

in this industry with the upcoming technology was analysed and reproduced as

lessons learnt.

3D printing is accurate, fast, durable and cost effective with a few disadvantages

attached to it which will be fixed in the near future. Based on the findings, it is

suggested to implement 3D printing into the organization while having a strong and

clear STS within.

The benefits were found to be reduced costs, manual labor and wastes. It is

highly environment friendly and allows customisation of desired products. It can

provide relief to those who’ve lost their homes in disaster zones. Projects can be

completed within few days so time will play a major role in competition.

Massive job losses, privacy concerns and supply chain reduction were the key

concerns along with the uncertainty of society welcoming this new technology. It is

sure that people will have their concerns on a 3D printed house as there isn’t a deep

foundation as well.It depends on how well society reacts to the technology for it to

achieve fame and acceptance.

As for a company that hasn’t yet implemented the technology, I suggest to wait

a few more years as full-fledged research and understanding of this technology is

required till it’s maximum utility and applications are realised. But when

implemented, the main focus should be shifted from the technical benefits to how the

printer is enabling innovation and creating value. Adopting to 3D printing affects

multiple areas and not just architecture and design. Training, Return on

investments, cost effective customization and productivity are some of the main

factors to be kept in mind.

Brief Description of the theory

Socio which means of the people/society and technical which means of

machines/technology, combines to give the term Sociotechnical. This system adds a

social obligation to the technology. It aims to ensure both elements are examined

together. The result of implementing this theory is to understand better how

organisational and social aspects affect the way tasks are getting done. It also enables

technology to connect people. For ex e-mail, chat rooms, networking sites etc. The

basis for adopting this theory is that the system design should be a mechanism that

takes into account both the factors (social and technical) that influence the

functionality and usage of computer-based systems.


The term socio-technical was introduced in the 1950's by the Tavistock

Institute as the manufacturing needs of industry confronted the social needs

of the communities.22 It has continually being tested and its practitioners have

aimed to achieve the need to humanize work through the redesign of jobs.

Basically the goal of STS is to yield positive outcomes from both factors which

is called joint optimization. Human needs should not be erased when

technical systems are around and has to be given equal importance. STS is

based on (1) the positive interaction between social and technical aspects of an

industry creates a better performed system. One unavoidable consequence of

mixing both factors is that people do not behave like technology and vice

versa. (2) This theory is all about united advancements.23 One of the best

socio-technical methods is the Effective technical and Human Implementation

of Computer-based Systems-ETHICS. ETHICS considers the addition of a new

systems as a part of a larger change process.

The main features of a socio-technical system are:

Should have interdependent parts

Should be able to adapt to external environments

Should have internal environment that has interdependent technical and

social systems

Goals can be met by more than one way

Performance depends on the united advancements of both factors

An associate at the aforementioned institute, Albert Cherns described few principles:

1. Compatibility- the objectives of the organization must be compatible with

process design.

2. Minimal critical specification- nothing more than the essential material

should be provided and means to achieve them.

3. The socio-technical criterion- deviations from the main objective must be

controlled.

22 Whitworth B. (2009) 23 Baxter G. Sommerville I. (2010)


4. The multifunctionality principle- variety of skills are necessary for a flexible

system.

5. Boundary Location

6. Information- should be given to groups that need to increase their efficiency

of work

7. Support congruence- support systems must be provided to ensure desired

behaviour

8. Incompletion- this shows that it is an iterative process and never stops

The most important lesson a STS can deliver is a value system. It shows that the

rights and needs of people should be given priority although technology and the

structure of an organization have tendencies to change.

While introducing 3D printing and implementing STS are not an easy task, it could

be achieved by introducing new methods and approaches to the organisation. The

installation of 3D printing will form a part of the entire organisational change

process. It could be evolutionary or purposely revolutionary. For example with the

coming of 3D printing there will be a reduction in workforce. Though various

systems can be defined as a socio-technical system, the approach to development is

rarely used. Such traditional approaches fail to understand the central goal of STSs.

The starting point is to understand the failures related to human aspects in order to

satisfy one of its main goals. It can understand what changes have to be made. Not

every individual knows how to operate or use a 3D printer. Because of this it slows

down the performance that it destroys the desired level of performance. A right

framework is needed to analyse and guide performance to ensure all subsystems are

working cohesively. Such approaches are more likely to be accepted by end users and

to deliver real value to shareholders.


1. Key features of technology

1.1 3D (three dimensional) printing is a part of process known as additive

manufacturing where object is created by adding material layer by layer. Additive

manufacturing is a process of making a physical object from a three dimensional

digital model, by laying down successive thin layers of material such as metals,

polyamides, biocompatible materials, resins, ceramics or textiles, salt, sugar or wood.


3D printers differ from one another by their usage but the basic key features of all

remain the same as below as per figure 1.1

Figure 2.1: How 3D printing works24

1.2 The features of 3D printing are as below:

Speed – The speed of the printer differs from one another the range of speed is

about 40 mm/s to max 100mm/s

XY resolution - 0.1 mm25

Printer size - 324mm X 312mm X400mm

Extruder - All metal, temperatures up to 250 degrees Celsius

Software: Slic3r+Printrun, Cura, kisslicer, MatterControl, Skeinforge

Firmware: Marlin

File Type: STL

Print Materials: 1.75mm PLA

Build Envelope (WxDxH): 125mm x 165mm x 120mm

2 Statement of context

2.1 Construction is a process of creating and building infrastructure or

facility. Residential construction is looking for efficient way of constructing

techniques in recent years, new construction technologies have been

researched and are being developed such as 3D printing technology called

additive building construction, similar to the additive manufacturing

techniques. This technique enables building flexibly small commercial or a

private house in less than 20 hours.

24 Grynol, B. (2015) 25 Krassenstein B. (2014)


3 Key benefits of 3D printing in construction of residential building

3.1 3D printing has become extensively popular from past decade in construction

industry, consumers have begun to innovate across wide range of industries which is

creating an industry disruption using due to the use of additive manufacturing

process.26 The key benefits of this technology such as below which are disrupting the

present market for construction are:

Manufacturing options – wide range of options in constructing and

customization is possible with structure, construction material, customized

specification and design of customer’s choice which is disruptive innovation

for architectural buildings since with 3D printing any structure would be easy

to build.

Rapid prototyping - 3D printing enables quick building of prototyping to

check the accuracy of design flaw and also the quality and functionality of it.27

Manufacturing speed - The speeding of manufacturing using 3D printing is

much faster than the traditional way of constructing houses. With 3D printing

we can build 10 houses in 24hours.

Low cost of production - The initial cost of setting up 3Dprinter is going to be

high, but the labour cost is going to reduce drastically, material expense

reduces and reuse of materials is possible hence recycling saves a lot of

material cost and is eco friendly

Disposable house - the most disruptive innovation of 3 D printing is the ability

to build a disposable house which is easily built in less than a day and easily

disposable as well.28

Complex structures- building a star shaped house was just a fantasy before 3

D printing came into picture. This can be a reality with this technique complex

structures are easily constructed and tested using prototyping.

Reduces energy consumption – The additive manufacturing reduces 70% of

energy consumption when compared to the traditional way making it more

disruptive in its way.

Eco friendly – This technique is not just quicker but also ecofriendly since it

produces very less waste compared to traditional method.

4 Key issues associated with implementing or exploiting this technology in the context

4.1 Additive manufacturing might have enormous impact on our lives, but that

doesn’t mean it’s going to be good for every business.29 The key issues of disruptive

innovation of 3D printing in construction would be as below:

26 Grynol B. (2015) 27 Baghel V. (2014) 28 Kaufman A. (2014) 29 Cotteleer, M. J. (2014)


Violation of copyrights – The availability of blueprints online may cause easy

replication of few buildings which have intellectual property rights. And this

violates the copyrights and would be against the law.

No manufacturing standards yet – There are no manufacturing standards

set yet with 3D printing hence it can’t be used for commercial purpose yet.

Employment reduction – less labour means less employ0ment and would

disrupt the labour community.

Accuracy – Hitting the right accuracy is very important when constructing a

batch of job if something goes wrong the whole batch has to be re printed.

again which would not only waste the construction time but also the material.

Limitation of raw material – Significant use of a single material causes for

limitation of use of different types of materials when compared to the

traditional way.

Durability and Robustness – building a house in less than a day how durable

and robust can it be would be a big question. The use of plastic for building a

house might not sustain all climatic conditions such as extreme hot

temperatures or extreme cold temperatures.

5 Lessons gained from applying disruptive innovation to the introduction of 3D printing into construction

5.1 The key takeaways of this additive manufacturing technology is the amount of

disruption it can cause in the construction industry in mere a decade is humongous.

The ability of building 10 houses in 20 hours was just a thought 10 years back now

it’s a possibility. As Mark says “Complexity is free with additive manufacturing”30.

Since the decade 3D printing has changed drastically. The sales of 3D printers are

going to increase by 2017 it will be $5 billion.31 As the demand of the technology

increases its market in the industries such as construction is going to expand and will

be disruptive for the old market.

5.2 3D printing is set to revolutionise the construction industry by finding different

ways of building houses faster and economical such as building house with plastic, or

reusable construction waste. 3D printing is disrupting the construction market by

additive manufacturing techniques. The 3D printing enables buildings equipped with

plumbing and electrical lines while printing the house.

5.3 This technology is replacing a lot of labour work such as construction labours,

builders, electricians and plumbers.32 Figures show that there are about 1 million

people employed in construction in Australia. The use of 3D printing would

drastically impact number of these employees. However the extensive use of 3D

30 Cotteleer M. J. (2014) 31 Wirth K.(2012) 32 John R. (2014)


printing in all markets could create many jobs such as technicians, developers for

building and designing 3D printing.33

5.4 3D printing can be used in different ways by different construction companies for

example an Amsterdam company called 3D canal house started building a 3D printed

house, they developed printed pieces using 3D printer and have clicking system just

like LEGO to assemble it on the construction site.34

6 Summary & Conclusions

6.1 3D printing is being used for many years now to build small objects, However,

some architects and builders decided to use 3D printing in construction industry35

and I believe it’s going to be disruptive innovation for the construction industry. 3D

printing also known as additive manufacturing is the future of construction industry.

This technology not only reduces the man power but also the amount of energy

consumption, 70% of energy is saved by using this method over the traditional.

6.2 In conclusion 3D printing until now is being used only in small scale projects

in the construction industry and could be used to build a full fledge building prior to

that lot of challenges are to be dealt before using it as a main construction

technology.36

6.3 Strongly recommend to use 3D printing for construction since It is very

ecofriendly method of constructing and economical as well as faster than the

traditional method.

Summary of Theory “Disruptive innovation”

Disruptive innovation is simple innovative idea that disrupts the existing

market by creating a better value to the existing market by introducing simple,

constructive, economical and easy accessibility that will redefine the product or

service in the existing market. The idea of this theory is to reinvent something that is

already existing and building on that platform for a greater innovation. Disruptive

innovation describes the form of revolutionary change.

The main characteristics of Disruptive innovation is to first start by identifying

opportunity i.e. recognising the opportunity like a small problem of hiring a cab that

Uber came up with. A simple mobile based app that was so disruptive to the cab

industry. Second think in user’s perspective eliminate all high end features that are

not used and stick to basics. And the innovation focuses on disrupting people’s

33 John R. (2014) 34 Heinsman (2015) 35 Husseini A. (2014) 36 Husseini A. (2014)


behaviour than the industry says with uber it did not disrupt the cab industry in fact

it disrupted the people’s behaviour, people are hiring taxi’s more often than before.

“Disruptive innovators thrive on creating difference first and focus on growth later”37

says Bernadette jiwa.

Figure 1 shows the framework of the disruptive innovation displays the

different components that are possible such as the Opportunity recognition,

opportunity development, solution development and exploitation and also displays

the external environments that impact this innovation.

Figure 3 Framework of Disruptive innovation38

3D printing is an emerging technology that is disruptive. 3D (three

dimensional printing) is a process by which a solid object is made from digital

models by adding successive layers of material such as metals, polyamides,

biocompatible materials, resins, ceramics or textiles, salt, sugar or wood.39This

technology is used across many industries such as health care, construction,

automobile and so on. In one of the industry i.e. manufacturing industry the rapid

development of 3D printing could disrupt the manufacturing market such as some

products like houses, possibility of building 10 homes in 24hours.

3D printing in manufacturing a house would be very disruptive due to its key

features that are:

1. Customized design – designing houses with complex geometric

design would take years of work for the architects and builders to

build a house now with 3D printing it will be very easy.

37 Jiwa B. (2015) 38 Thomond, P., Herzberg, T. and Lettice, F. (2003) 39 Jang S. (2009)


2. Assembly – The assembly of the parts in the 3D printing is much

faster and quicker.

3. Disposable houses – who would have imagined houses, could be

disposed when you don’t want to live anymore in that house. With

3Dprinting it’s possible. With 3d Printing it not just reduces the

waste produced but the reusability of the material increases.

4. Faster construction – Constructing 10 houses in 24 hours would

definitely revolutionise the manufacturing industry after few years

5. Eco friendly – Reduces energy consumption by 70% compared to

traditional construction method, use of recycled materials is also

possible with 3Dprinting.

6. It will be a huge disruption for labour unions; since 3Dprinitng

would reduce man labour drastically hence the huge jobs would

reduce evidently.

3D printing in construction would open up whole new future for construction

industry. 3D printing could become the future of infrastructure hence would a

disruptive innovation since it’s a smarter way of constructing houses its faster more

evident, uses very less construction materials and requires low labour and is more

ecofriendly since less waste is reduced.


Key features of 3D printing technology 3D printing is part of a process known as an additive manufacturing where an object is created by adding material layer by layer from a digital file.In final printed object/product each of these layers can be seen as a thinly sliced horizontal cross-section . The process digitally models a structure of the object that needs o be printed in a design program and then consecutively sends out this object blueprint to the 3D printer where the design software further “slices” the object into several layers.2With the object information in it, the 3D printer then constructs the object by making repeated passes. At each pass, a thin layer of material is deposited over previously deposited material. The layers are created from “slice” of information associated with the digital model.

The type of the item that is to be printed and the corresponding technology are critical factors in forming the material and method of application. For example, 3D printer can create objects using variety of materials including glass, plastic , metal, even human cells. These materials can come in a form of powder, liquids, filaments or sheets. These material can be incorporated by several means such as spraying, extruding or setting them with a laser beam.

There are some common features for all 3D printer, such as:

• Simplicity- 3D printer has simple and easy to use software to handle the technical aspects of printing automatically . This feature may allow to simplify the construction process.


• Usage of special modelling software - 3D printer create an animated print imitation by using 3D modelling software for example, CAD (Computer Aid Design) which allows users to identify errors even before printing.

• Auto clean-up - 3D printer has both auto-generated and customized support structures. With these features, operations can be added or removed by one-click for the model construction and simple post-process clean-up1

• 3D printing is an additive process of making a 3-D object of virtually any type of complex geometric pattern from a digital image using a massive amount of mediums.

• Advanced features like mesh repair utilities used to check an error while uploading design file for 3D printing.40

Previously, the application of 3D printing technologywas limited to manufacturing

smaller items only. The initial works produced cups, model cars, or guns.41 Research

institutions and architectural firms arenow concentrating ondeveloping technology

that allowsthe fabrication of whole buildings by using 3Dprinting.Currently such

technology is emerging. In China, a company named "Winsun" has reported that ten

houses were built within just one day with 3D printing technology and each cost

lower than $LUS5,000.42

2. STATEMENT OF THE CONTEXT

Designing complex shape and form of a building is now not only limited in Architects imagination. Though some complex design has been achieved by offsite factory based manufacturing techniques but still there is limitation to the level of doable complexity. Also in usual construction method construction firms are facing problems such as,

• Traditional method is slow in process

• Labour intensive and inefficient

• Hazardous and dangerous

• Wasteful

• Generate a lots of emission

• Most importantly because of a number of trades are involved, mismanagement occurs and finally the whole process is costly and over budget.

All these problems might be solved by using3D printing technology also known as "Contour crafting". In this method printing will be done with a large sized printer that uses a special concrete and composite mixture. 43The material is deposited through a nuzzle and the building is constructed layer by layer. The basic methodology is same as the idea behind of a traditional method of construction which is also done in layers as in foundation block, laying bricks etc. One of the notable quality of the structure is that it is hollow which allows less amount of materials and permitting space for other

40 Michael Molitch-Hou(2014)

41 Peter K. Doely (2014)

42 The Urban developer

43 VIATechnik


building services such as plumbing, electrical network installation etc. inside of the structural elements. Other construction based and building interior tasks such as tiling, painting and so on may also be done by special 3D printer in near future.

3. KEY BENEFITS OF 3D PRINTING IN CONSTRUCTION

This report explains the potential of 3D printing technology in context of construction that can be applied in residential development project. The preliminary idea can be substantially improved by introducing efficient theories to make it more accessible, secure and cost-effective. This report also discusses on a particular theory that can be adopted with 3D printing for facilitating construction. 3D printing has several advantages over conventional construction methods. For example,

• Time & cost- Finance, materials and labour costs are the three most commonly considerable factors in most of the construction projects. The use of 3D printing can potentially reduce significant amounts of cost by limiting entire project running times and by using small amount of wasted resources.

o Reduce equipment- With 3D printing, an idea can be directly imported from the designer software into the final product, thus eliminating number of traditional manufacturing steps, including procurement of individual parts, using moulds and machine to crave parts from blocks etc. Khoshnevis projects that the construction cost of a house made with Contour Crafting will be one-fifth in compared to the cost of the same house constructed with conventional construction.2

o Reduce labour cost - Minimal human effort is another notable feature of 3D printers. The limited time frame and overall automation process will eliminate the necessity of having man hours - both labour and supervision positions. With minimal trades involvement whole construction cost eventually goes down.

o Faster and accurate construction – A 3D printer transfers the digital model into a physical one; errors that arise can only be due to faults in the digital model or the materials used 44 .Reducing time will also require reduced financial costs and overhead. Less time will also demand less financing costs and overhead.

o Reduced waste generation &Environmentally friendly – During construction, important components can be printed and those which are not required to print right away might be recycled. Those recycled materials can be later utilised for producing construction materials.

• Far more safe- The automation of construction process reduced the occurrences of losses and injuries by replacing dangerous jobs on site with printing processes.

• New capabilities-3D printing provides design flexibility in terms of printed architectural components that are totally free by typical design constraints. The

44 Forconstruction(2014)


ability to execute curvilinear forms, without any additional cost makes the process opens up a whole new area of possibilities for architects everywhere.

• Disruptive potential- This 3D printing technology is still at in early execution stage.But initial implementation shows that the improvements on accuracy, speed and quality of materials in 3D printing technology will open new doors in manufacturing strategy. Dr.BehrokhKhoshnevis’ research at the University of Southern California which resulted in a 3D printer that can build a house in 24 hours.45The other promising aspect of3D printing technology is that it not only can process same prototype houses but a colony of houses, each with possibly a different design, embedded in each house all the conduits for electrical, plumbing and airconditioning.6This is a remarkable innovation for construction industry. Therefore, though the adaptation of this technology still in its primary stage, there is a huge potential to replacing the existing system.

The application area of the discussed technology is obviously construction industry. But more specifically Until recent years models were built by hand, often taking a long time. Thus, architects are often forced to show their clients drawings of their projects. 46 Now by using 3D modelling software architects or architectural firm can generate prototype model to show their clients what would be the final product ,in a small amount of time. Using 3D printing, these firms can reduce times of production by 50 to 80 percent, producing scale models up to 60 percent lighter than the machined part without compromising strength.47

4. KEY ISSUES ASSOCIATED WITHIMPLIMENTING

OR EXPLOTING 3D PRINTING INCONSTRUCTION

3D printing technology has great potential in construction industry although there

are several issues that must be address first before 3D printing can be implemented

as a feasible solution in construction sector. Five most critical challenges related with

cost, reduce workforce, lack of skilled operator, allocation risk and legal challenges.

• 3D printer itself is quite expensive. Cost can also be associated with transportation and time.For example, getting printer to and from the site and required additional time for the components are created in situ may cost extra expenses.

• Automation will reduced employee numbers in the industry, since the 3D printer does most of the work .Khoshnevis argues that the technological advances will act to shift the kind of work to be done in the construction industry rather than simply reduce the workforce2.

• To print anything,3D printer normally need a model created in CAD software. Currently there are not many CAD operators out there. Therefore, it is necessary to create skilled worker.

45 Khoshnevis,et al(2001)

46 Knippers, E.(2015)

47 stratasys (2015)


• Allocation risk-

o Any new technological advancement, there are practical and legal issues which should consider first. To create a proper foundation of building durability of construction material is required. Advances in concrete materials technology will be required before 3-D printing technology can be widely applied in the building and infrastructure sectors”48Concrete mixtures combined with the necessary structural characteristics and long-term durability when cured, is not developed yet.

o One risk to consider are contractual warranties. AIA Document A201, for example, contains warranties assuring the owner that 1) the materials and equipment furnished will be of good quality and new unless otherwise required, 2) the work will be free from defects not inherent in the quality required or permitted, and 3) work will conform with the requirements of the contract documents. None wants to take on a budding technology that does not work out as promised. Therefore, it is necessary to put the technology in the appropriate legal framework.2

o A super-sized 3D printer is used in construction site, getting the printers for large in situ components and store the printer can be another liability issue.

Implementing the technology will not be without its challenges. From the

perspective of construction industry, companies will need to determine how these

technologies will change the industry and what legal issues will need to be consider

in order for them to be utilized. Before incorporating these manufacturing methods

CEO of the firm should consider how the technology changes their exposure to risk

and should consult with knowledgeable professionals.

5. Lessons gained from applying TRANSACTION COST Theory to the introduction of 3DPRINTING Technology into CONSTRUCTION Context

Transaction cost associated with all cost incurred to the whole process from

production to execution. In the context of construction when any consultancy firm

decide to use 3D printer for construct the CEO can discuss with specialist about what

transaction cost may occur. For example, if a small company got a contract to build

one/two houses. In this circumstance it is not ideal for the company to buy 3D

printer because it’s very expensive instance the company could rent one. Again for a

large company with lots of manufacturing contract they can own a printer. In this

case the printer will be an asset for the firm. Although the printer would create extra

maintenance cost but for long term benefit it’s better to buy one.

48 Josh M. Leavitt(2015)


Another example is 3D printer may not always have carried to the site for in -situ

construction. Some component might have built in firm then assemble in site. Again

the decision may vary if transportation cost is higher than the labour cost.

Incorporating knowledge of transaction theory will help to understand the

importance of using 3D printer to minimize construction cost and save almost one fifth of construction time and increase profit for the firm.

6.Summary&Conclusion

This report discussed on 3D printing in particular context which is residential

construction and also issues related with implementation of the technology in the

context by applying Transaction cost theory. The idea is to build efficient, affordable

houses with low cost and minimal time to help the associated industry and also

general people who cannot afford lavish high cost house. The promising preliminary

result of current 3D printing method shows the potential of the technology in

previously discussed context. Right now price of 3D printer and material used in 3D

printer is much expensive but using recycled material can lower the production cost.

Researchers trying to minimize material cost and also determine to find out solution

of related legal issues by consulting with Architects to make the technology more

efficient and reliable. The various types of materials used and the combination of

materials in construction should be also recognized. For this type of technology to be

successfully adapted by the construction industry, much further research has to be

done to produce and refine 3D printers capable of working on construction projects.

Finally, the rich literatures of Transaction cost theory can motivate CEO of

Architectural consultancy firm to a large extent by helping them in addressing risk

and issues of implementing 3D printer and provide them knowledge of the changing

impact upon numerous facets of the modern economy10.

Brief Description of the theory

Transaction cost theory

In economics and related disciplines, a transaction cost is a cost incurred in making

an economic exchange wares Transaction cost theorists state that the total cost

incurred by a firm can be grouped largely into two components 10 transaction costs

and production costs.

Transaction costs can have defined as the costs related with the work of people and

machines that perform the primary processes, on the other hand production costs

include the costs of to create and distribute the goods or services being produced.

Firm will arise when they can arrange to produce what they need internally and avoid transaction cost.

Transaction cost theory (TCE) has traditionally examined the customer-supplier

relationship in the context of a contractual arrangement. This relationship is

associated with TCs. A number of different kinds of transaction costs exist including,


• costs of information negotiation

• competitive advantage

• contract administration and management

• market structure, enforcement, and measuring/monitoring performance impact on transaction costs.

This customer - supplier relationship enables the development of appropriate

strategies, such as,

• long-term agreements and alliances

• to eliminate the risk associated with contracting uncertainty

• limiting the number of instances of bargaining or opportunism and asset specificity10.

Transaction cost are low when following condition occurs:

Organization are exchanging nonspecific goods and

services

• Uncertainty is low

• There are many possible exchange patterns

Transaction cost are increase when following condition occurs:

• Organization start to exchange specific goods and services

• Uncertainty increases

• Number of possible exchange patterns falls

TCE could generate a valuable understanding of the costs associated with

coordination, inspection, translation, incentives, transactions, and other

interactions. 49Transaction cost could be both internal or external. The benefit

associated with this theory is by adapting transaction cost theory a firm could decide

whether or not and how much resources the firm can outsource to increase its assets.

How the theory can be applied in consultancy firm:?

CEO of construction firm can use transaction cost theory to choose an inter -

organization strategy,

• Locate the sources of transaction cost that may affect an exchange relationship and decide how high the transaction cost is likely to be

• Estimate the transaction cost savings from using different mechanism

• Estimate the cost of operating that mechanism

• Choose a mechanism that gives the most transaction cost savings with less maintenance cost.

49 MGI disruptive technology


In construction project costs can be split into three categories: finance, materials and labour. 3D printing could potentially erase significant amounts of money in bringing construction projects to market, through shorter project times and fewer wasted resources. For example, WinSun have continued to make waves with their 3D-printed homes, printing 10 affordable single-story houses in just 24-hours. Each house was around 650 square feet and cost under $5000 each to make. Again, the company used recycled construction waste and cement to ‘print’ the homes 3. According to an article from CNET, Winsun says the 3D process saves between 30 and 60 percent of construction waste, can reduce production times by 50 to 70 percent and reduce labour costs by 50 to 80 percent .4

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