Delft University of Technology

Double curved concrete printing

Printing on non-planar surfaces

Schipper, Roel; Borg Costanzi, Chris; Bos, Freek; Ahmed, Z; Wolfs, R.

Publication date2017

Citation (APA)Schipper, R., Borg Costanzi, C., Bos, F., Ahmed, Z., & Wolfs, R. (2017). Double curved concrete printing:Printing on non-planar surfaces. 3TU speerpunt bouw.

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POESIA T SENSORS I N A S P H A L T Univers i ty o f Twen te : dr. ir. Se i r ge i M i l l e r , mr. J o y r a j C h a k r a b o r t y , J u r i a n v a n d e r V e g t , D a a n B r i n k e r i n k - Technical Univers i ty o f De l f t : prof ,

dr. ir. S a n d r a E rkens , dr. X u e y a n L iu , dr. K u m a r A n u p a m - Boskalis BV: mr. B e r w i c h S luer , dr. ir. M o h a m a d M o h a j e r i - Technob is S O L A R BIKES: USER A C C E P T A N C E E indhoven

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dr. M A r c h . M i c h e l a Tu r r i n , M A r c h . M .Tee i i ng , ir. Paul d e Ru i te r , M a r k v a n Erk, dr. ir. arch. M a r t i n T e n p i e r i k , dr. i n g . Tha le ia K o n s t a n t i n o u M S c , Prof. Dr . - Ing. U l r i ch K n a a c k - E i ndhoven

Universi ty o f Techno logy : ir. A r n o P r o n k , P ro f Dr . - Ing. Pa t r i c k T e u f f e l , A r t h u r v a n L ier , Rens V o r s t e r m a n s , E l ine D o l k e m a d e , M a r i e d e K l i j n M S c , ir. Roe l L o o n e n , prof . dr. ir. J a n

H e n s e n - KIWI So lu t ions : D i c k V l a s b l o m SPYING T H E U N D E R G R O U N D Univers i ty o f Twen te : L e o n o l d e S c h o l t e n h u i s - De l f t Univers i ty o f Techno logy : Dr . - Ing. Sisi Z l a t a n o v a , X a n d e r

d e n D u i j n B S c , A n n a - M a r i a N t a r l a d i m a M S c , E v a n g e l o s T h e o c h a r o u s MSc. - Mun ic ipa l i t y o f Ro t te rdam - Recognize U N L E A S H T H E B U I L D I N G BOTS E indhoven Univers ty o f

Techno logy : A a n t v a n d e r Z e e - De l f t Universi ty o f Techno logy : Paul d e Ru i t e r - TBI Kenn is lab: H a y o M e i j s DE REUS V A N S C H I M M E R T E indhoven Univers i ty o f Techno logy :

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Techno logy : I m m a n u e l G e e s i n g M S c , prof.dr. ir . B a u k e d e V r i es - S t ich t ing Bedr i j ven te r re in H e l m o n d : Fr i t s R u t t e n T R A N S I T I O N T O W A R D S D C M I R C O GRIDS E indhoven Universi ty

of Techno logy : Evi P l o u m p i d o u , prof . dr. S j o e r d R o m m e , dr. M a d e l e i n e G i b e s c u - A B B BV: A r n o B r o n s w i j k - D C F lexhouse: H a r r y S t o k m a n - D i rec t Cur ren t BV: P e p i j n v a n

W i l i g e n b u r g - NEBER: W i l P a u l u s - EPM BV S M A R T LIVABLE CITIES t r e k k e r s g r o e p : Teun B o k h o v e n - T S Energ ie , TKl Urban Energy, T o m v a n E c k - V N O - N C W / B o u w e n d N e d e r l a n d ,

Pa t r i ck K o i m a n s - B o u w e n d N e d e r l a n d , A l e x a n d e r S c h m e t s - 4 T U . B o u w , L i e s b e t v a n Z o o n e n - Erasmus Univers i te i t R o t t e r d a m ; v o o r b e r e i d i n g s g r o e p : C a r m e n A a l b e r s - W a g e n i n g e n

UR, M a r t j e v a n A n k e r e n - Na t ionaa l Reg ieo rgaan Prak t i j kger ich t O n d e r z o e k Sla, Luca B e r t o l i n i - Un ivers i te i t van A m s t e r d a m , C o l e t t e Bos - N a t i o n a l e W e t e n s c h a p s a g e n d a , G e e r t -

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N I O O - K N A W , M a a r t e n v a n S t e e n - Un ivers i te i t T w en te , Sand ra S t o r m - Ve ren ig i ng H o g e s c h o l e n , P e t e r Paul v a n ' t V e e n - T N O , J a n V r e e b u r g - W a g e n i n g e n UR; d ig i ta le

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d e r H o e v e n - Technische Univers i te i t De l f t , J e r o e n K l u c k - H o g e s c h o o l van A m s t e r d a m , R e i n e k e v a n d e r K o l k - A i r b u s De fense & Space, O l a f v a n K o o t e n - I nho l l and , Ir is K o r t h a g e n

- Rathenau Inst i tuut , C i n t K o r t m a n n - Q u a n t b a s e , F r a n k Kres in - W a a g Society, G e r t K r u i t h o f - A S T R O N , R o g i e r K u i n - B O V A G , M i c h i e l d e L a n g e - Univers i te i t Ut recht , T h o m a s

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Peek - H o g e s c h o o l Ro t t e rdam, H a n La P o u t r e ^ C W l A m s t e r d a m / Technische Univers i te i t De l f t , J a s p e r R o o d e n b u r g - N W O , D i c k S c h m i d t - T N O , L iana S j e r p s - K o o m e n - TKl Urban

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REALITY E indhoven Univers i ty o f Techno logy A a n t v a n d e r Z e e , De l f t Unvers i ty o f Techno logy A l e x W a n d I , 4 T U . B o u w A l e x a n d e r S c h m e t s , De l f t Unvers i ty o f Techno logy A n a A n t o n ,

4 T U . B o u w / Univers i ty o f Twente A n d r é D o r é e , De l f t Universi ty o f Techno logy A n n a M a r i a N t a r l a d i m a , De l f t Univers i ty o f Techno logy A n n e S t r u i k s m a , De l f t Universi ty o f Techno logy

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Universi ty o f Techno logy B a h m a n H a s h e m i , 4 T U . B o u w / E indhoven Univers i ty o f Techno logy B a u k e d e V r i es , De l f t Univers i ty o f T e c h n o l o g y B r a m B o t t e r m a n , Car l ien Rood ink

Consu l tancy Car l i en R o o d i n k , De l f t Univers i ty o f Techno logy Caro la H e i n , De l f t Univers i ty o f Techno logy Cas v a n d e r Z a n d e n , E indhoven Univers i ty o f Techno logy C h e n H u n g C h u ,

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Universi ty o f Twen te D e n i s M a k a r o v , Eneco D e n n i s R a m o n d t , KIWI so lu t ions D i c k V l a s b l o m , S u m m u m / Block Research G r o u p , ETH Zür ich D i e d e r i k V e e n e n d a a l , c reat ive pro jec ts D r é

K a m p f r a a t h , De l f t Univers i ty o f Techno logy E d w a r d V e r b r e e , bu reaubakke r El ise B u i t e r , E indhoven Univers i ty o f Techno logy Ella B raa t , De l f t Univers i ty o f T e c h n o l o g y Enaya t Hosse in i

A r i a , 4TU .Bouw / De l f t Universi ty o f Techno logy Er ik S c h l a n g e n , De l f t Univers i ty o f Techno logy E r w i n J a c o b s , De l f t Univers i ty o f Techno logy Fa id ra O i k o n o m o p o u l o u , Univers i ty o f

Twente Fa r i d V a h d a t i k h a k i , E indhoven Univers i ty o f Techno logy F e i x i o n g L iao , De l f t Univers i ty o f Techno logy F o t e i n i S e t a k i , 4 T U . B o u w / De l f t Univers i tv ^ - f ' ) logy F r a n k v a n d e r

H o e v e n , E indhoven Univers i ty o f Techno logy F reek Bos , E indhoven Univers i ty o f Techno logy G a m z e D a n e , Socrates Hans J a a p M o e s . Y.^r.\-- " 5ar, De l f t Universi ty

o f Techno logy H e n r i e t t e B ier , Univers i ty o f Twente H o s s e i n y A l a m d a y , E indhoven Univers i ty o f Techno logy l ou l i a Os^-r.^'— B o e r , Univers i ty o f

Twente J a n i n e P ro f i j t , De l f t Univers i ty o f Techno logy J a v i d J o o s h e s h , E indhoven Univers i ty o f Techn'-^ i - - yjOf^^*^^ l i vers i ty o f Twente

J o y r a j C h a k r a b o r t y , De l f t Univers i ty o f " techno logy J u a n A z c a r a t e , De l f t Univers i ty o f Techn . ^ Ide S c h o l t e n h u i s ,

De l f t Univers i ty o f Techno logy L ida B a r o u , Ha rmon-E / B redeSt roomversne l l i ng M a a r t é i \nnOVa^ ofOV®̂ '̂ ^ M a r i a Hansch ,

E indhoven Univers i ty o f Techno logy M a r i e d e K l i j n , De l f t Univers i ty o f Techno logy M a r k v a n

researcn y h n o l o g y M i c h e l a

Tu r r i n , E indhoven Univers i ty o f Techno logy M i c h i e l R i t z e n , De l f t Universi ty o f Techno logy M •ffOrO _ e ' i tVSS ^ o f Techno logy

N a d i a R e m m e r s w a a l , Panos Sakkas , E indhoven Univers i ty o f Techno logy Pa t r yc ja P u s t e l n i k ^ hnica^ UoW© m o l o g y Pau l i ne

v a n d e n B e r g , SBRCURnet Per ica Savanov i c , De l f t Univers i ty o f Techno logy P ie t v a n S taa lo ^ Qut^^ - . ^ . L y oT Twente Pr iya D a r s h i n i

C h e y y a r N a g e s w a r a n , De l f t Univers i ty o f Techno logy Q i n g p e n g L i , E indhoven Univers i ty o f Te • o i e s e n . E indhoven Univers i ty o f Techno logy

Ri jk B lok , U N S t u d i o R o b H e n d e r s o n , E indhoven Universi ty o f Techno logy Roe l L o o n e n , De l f t L _ o c n i p p e r , Eneco R o n a l d R o o t , 123DV arch i tec ten Ro t te rdam

S a m a n e h Rezvan i , De l f t Univers i ty o f Techno logy S e y e d S e d i g h i , 4 T U . B o u w / bu reaubakke i -<jK.Ker, De l f t Univers i ty o f Techno logy Sina M o s t a f a v i , E indhoven Univers i ty o f

Techno logy S j o n n i e B o o n s t r a , Q u b y S t e p h e n G a l s w o r t h y , De l f t Univers i ty o f Techno logy Teles i i la B r i s t o g i a n n i , De l f t Univers i ty o f T e c h n o l o g y Tha le ia K o n s t a n t i n o u , De l f t Univers i ty

o f Techno logy T o m m a s o V e n t u r i n i , E indhoven Universi ty o f Techno logy T o r s t e n S c h r o d e r , De l f t Univers i ty o f Techno logy Truus H o r d i j k , 4 T U . B o u w / De l f t Univers i ty o f Techno logy

U l r i ch Knaack , De l f t Universi ty o f Techno logy V a g o s T h e o c h a r o u s , De l f t Univers i ty o f Techno logy V a l e n t i n i S a r a k i n i o t i , E indhoven Univers i ty o f Techno logy W e n J i a n g , E indhoven

Universi ty o f Techno logy W e n s h u Li , C i ty o f Ro t t e rdam, Indones ian D ispora N e t w o r k W i w i T j i o o k , Vo lkerWessels iCi ty W o u t e r B e e l e n , E indhoven Univers i ty o f T e c h n o l o g y X i a o t e n g

Pan I N N O V A T I O N E X P O S i e b e B a k k e r , M a r c e l B i l o w , F rank v a n d e r H o e v e n , N a d i a R e m m e r s w a a l , M i c h e l a Tu r r i n CITY O F T H I N G S S i e b e B a k k e r , El ise B u i t e r , M a t t h i j s d e

D e c k e r e , K i m D e g e n , D r é K a m p f r a a t h , D e n n i s R a m o n d t , R o n a l d R o o t , M a r l e t S a u e r w e i n , Frans S c h u p p , F r a n k v a n d e r H o e v e n , N u n o V a r a n d a s , Teun V e r k e r k REAL A D D I T I V E

M A N U F A C T U R I N G S i e b e Bakke r , El ise B u i t e r , M a r c e l B i l o w , L e n n e a r t v a n C a p e l l e v e e n , J e r o e n C o e n d e r s , Ch r i s B o r g C o s t a n z i , U l r i ch Knaack , Pau l d e Ru i te r , V a l e n t i n i S a r a k i n i o t i ,

Roe l S c h i p p e r , H o l g e r S t rauss , M i c h e l a T u r r i n , D e n n i s d e W i t t e , A a n t v a n d e r Z e e 3 D C O N C R E T E P R I N T I N G FOR S T R U C T U R A L A P P L I C A T I O N S E indhoven Univers i ty o f Techno logy

T h e o Sa le t ; De l f t Univers i ty o f Techno logy 6 5 + BEST N E I G H B O U R H O O D C O N C E P T S : H A P P Y S E N I O R L I V I N G E indhoven Univers i ty o f Techno logy : l ou l i a O s s o k i n a , De l f t Univers i ty

o f Techno logy A D A P T I V E J O I N T S W I T H V A R I A B L E STIFFNESS E indhoven Univers i ty o f Techno logy : Q i n y u W a n g , De l f t Univers i ty o f T e c h n o l o g y E X C A S A F E Z O N E Univers i ty o f

Twente : L é o n o l d e S c h o l t e n h u i s , De l f t Univers i ty o f Techno logy , E indhoven Univers i ty o f Techno logy G E O P O L Y M E R C O N C R E T E BRIDGE De l f t Univers i ty o f Techno logy : dr. G . Ye,

E indhoven Univers i ty o f Techno logy RE3 GLASS - A REDUCE/REUSE/RECYCLE STRATEGY De l f t Univers i ty o f Techno logy : Teles i i la B r i s t o g i a n n i , Univers i ty o f Twen te RE-PRINTING

A R C H I T E C T U R A L HERITAGE De l f t Univers i ty o f Techno logy : Ca ro la H e i n , E indhoven Univers i ty o f Techno logy T E R R A - I N K : A D D I T I V E E A R T H M A N U F A C T U R I N G FOR E M E R G E N C Y

ARCHITECTURE De l f t Universi ty o f Techno logy : M i c h e l a Tu r r i n , E indhoven Univers i ty o f Techno logy

Lighthouse Projects 2017 4TU • Bouw center of excellence for the built environment

C o m b i n i n g t he t echno log ies o f 3 D concre te p r in t i ng and f iber re in fo rced concre te , e lemen ts m a d e by 3 D concre te p r in t i ng can b e c o m e su i tab le f o r st ructural app l ica t ions . A structural ly safe fu l l scale pav i l ion wi l l b e p r i n ted t o f inal ize t h e pro jec t .

E i n d h o v e n U n i v e r s i t y o f T e c h n o l o g y D e l f t U n i v e r s i t y o f T e c h n o l o g y

Research in to locat ion a n d hous ing t y p e pre ference wil l

be used t o des ign l iv ing concep ts f o r t h e elder ly. T h e

feasib i l i ty o f t h e concep ts wi l l b e tes ted in a p i lo t .

E i n d h o v e n Un i ve r s i t y o f Tech D e l f t Un i ve r s i t y o f T e c h n o l o g y

tura l j o in ts w i t h adap t i ve st i f fness capabi l i t ies , wi l l a l low con t ro l ove r t h e shape a n d sti f fness o f t h e structures. This can lead t o m o r p h i n g and d e p l o y a b l e structures, w i th f o l d a b l e s t ructures, act ive fagade systems or o r i gam i insp i red st ructures.

Q i n y u W a n g - Q.W,

E i n d h o v e n U n i v e r s i t y o f T e c h n o l o g y D e l f t Un i ve r s i t y o f T e c h n o l o g y

The d e v e l o p e m e n t o f an a u t o m a t e d system tha t genera tes excavat ion safety maps t o enab le u rban p lanners , con t rac to rs a n d excavator ope ra to rs t o rpake m o r e i n f o r m e d dec is ions a b o u t whe re a n d h o w t o c o n d u c t excavat ion act iv i t ies.

H ËMjmmmmmmmmmÊÊÊÊmÊÊm Exp lo r ing t h e pos ib i l i t ies o f us ing 3 D scann ing a n d 3 D p r in t i ng in t h e restorat ion a n d / o r renova t ion o f archi tectura l her i tage . As feas ib i l i ty s tudy a f r a g m e n t o f t h e Hyppo ly tuske rk M i d d e l s u m wi l l b e recrea ted .

li >f^<iiUi^jiiiinti(L< u twen te .n l

U n i v e r s i t y o f T w e n t e

D e l f t Un i ve r s i t y o f T e c h n o l o g y

E i n d h o v e n Un i ve r s i t y o f T e c h n o l o g y

le f i rst s tep t owa rds c e m e n t f ree cons t ruc t i on ,

st ructural e l emen ts wi l l b e d e s i g n e d , manu fac tu red a n d

t e s t e d . This p r o o f o f c o n c e p t wi l l b e used t o cons t ruc t

t h e f irst p re fab r i ca ted g e o p o l y m e r concre te b r i d g e .

h n o l o g y

o f T e c h n o l o g y

The des ign a n d manu fac tu r ing o f compress ive bu i l d i ng e lemen ts m a d e f r o m glass. Mater ia l use is r e d u c e d t h o u g h t h e d e s i g n , e lemen ts can be reused t h r o u g h dry -assembly a n d e lemen ts are m a d e f r o m recyc led glass.

sa l fBRi i iNi

D e l f t Un i ve r s i t y o f T e c h n o l o g y

E i n d h o v e n U n i v e r s i t y o f T e c h n o l o g y

Using local a n d recyc led mater ia ls w i th 3 d p r in t i ng t echno logy , a so lu t ion wi l l be c rea ted fo r t h e hous ing emergenc ies in post -d isaster a n d m ig ra t i on crisis events . T h e a im is a l ow cost d w e l l i n g un i t m a d e o f ear th -based mater ia ls .

4 T U . B o u w r e p r e s e n t s t h e c o l l a b o r a t i o n b e t w e e n t h e f o u r Technica l

Un i ve rs i t i es in t h e N e t h e r l a n d s o n t h e l a r g e t o p i c o f ' T h e Bu i l t

E n v i r o n m e n t ' . T h e c o o p e r a t i o n cons is ts o f t h e D e p a r t m e n t o f t h e

Bu i l t E n v i r o n m e n t a t T U E i n d h o v e n , t h e f a c u l t y o f E n g i n e e r i n g

T e c h n o l o g y a t T w e n t e Un ive rs i t y , t h e f acu l t i e s o f A r c h i t e c t u r e a n d Civ i l

E n g i n e e r i n g a n d Geosc i ences a t T U D e l f t a n d W a g e n i n g e n Un ive rs i t y .

T h e g o a l o f t h e 4 T U . B o u w i n i t i a t i v e is t o p r o m o t e c o l l a b o r a t i o n

b e t w e e n t h e m e m b e r f a c u l t i e s , i ndus t r i a l p a r t n e r s a n d g o v e r n m e n t , in

o r d e r t o m e e t t h e g r a n d cha l l enges a h e a d .

Bui l t Env i ronmen t is t h e b i o t o p e o f t h e m o d e r n c i t izen, p r o v i d i n g

infrastructure f o r t ranspor t , de fence against f l o o d i n g , shelter, space f o r

w o r k i n g , m e e t i n g and leisure act iv i t ies, etc. The d e m a n d s u p o n rel iabi l i ty,

safety and c o m f o r t o f these structures is con t inuous ly increasing.

Meanwh i l e t h e Bui l t Env i ronment sector is c o n f r o n t e d w i th e n o r m o u s

chal lenges like scarcity o f resources, c l imate change , acce lera ted

popu la t i on grovr th and d e m o g r a p h i c changes. These cha l lenges requi re

j o i n t s t rategies a n d co l labora t ion betw/een end-user, academia , t h e

industry and g o v e r n m e n t a l agenc ies , t h e so-ca l led g o l d e n t r iang le .

There fo re , in t h e con tex t o f t h e Du tch 'Na t i ona le W e t e n s c h a p s a g e n d a ' ,

4 T U . B O U W , w i th its par tners , has iden t i f i ed t h e impo r t an t , soc ieta l a n d

scient i f ical ly re levant research t hemes : ' D e Toekomst W o r d t G e b o u w d ' , as

wel l as t he 'Bui l t Society Smart Reality' u rgency a n d a m b i t i o n ' m a p ' .

Relevant t h e m e s have been ut i l ized as con tex t fo r t he 4 T U . B o u w L igh thouse p r o g r a m m e s 2016 and 2017 . In 2016 f i f teen d e d i c a t e d , fast t rack innova t ion pro jec ts have been c o m p l e t e d , all address ing aspects o f t h e a g e n d a and m a p . These pro jec ts p rov ide a p r o o f o f c o n c e p t - o r fai lure - o f new techno log ies t ha t wi l l con t r i bu te t o so l id approaches and so lu t ions t o t h e cha l lenges ahead , fo r ail s takeho lders . In 2017 e igh t more L igh thouse Projects wi l l start. A lso , a d e d i c a t e d PDEng- t ra in ing p r o g r a m m e con t r i bu tes t o t h e fu tu re avai labi l i ty o f we l l - t ra ined special ists, meanwh i le b r i d g i n g t h e g a p b e t w e e n academia and the market . 4 T U . Bouw str ives t o respond rapid ly t o t h e ever faster changes, o f ten e m e r g i n g b o t t o m - u p , t ha t new techno log ies b r i ng a b o u t , by organ iz ing workshops , b ra ins torms and t ra in ing sessions w i th re levant s takeho lders , and by f o r m i n g d e d i c a t e d consor t ia t ha t act jo int ly . On ly by such j o i n t act ions w i th respect t o t h e u rgen t t h e m e s are pos i t i ve changes e x p e c t e d t o h a p p e n .

M i c h e l a Tur r in - m. tur r in@tudel f t .n l

D e l f t U n i v e r s i t y o f T e c h n o l o g y

E i n d h o v e n U n i v e r s i t y o f T e c h n o l o g y

Scient i f ic D i rec to r - U l r i ch K n a a c k

Execut ive D i r e c t o r - A l e x a n d e r S c h m e t s

Cu ra to r - S i e b e B a k k e r

A m b a s s a d o r s

De l f t Univers i ty o f Techno logy - A r ch i t ec tu re : F r a n k v a n d e r H o e v e n

De l f t Univers i ty o f Techno logy - Civi l Eng inee r ing a n d Geosc iences : E r i k S c h l a n g e n

E indhoven Univers i ty o f Techno logy - Bui l t Env i ronmen t : B a u k e d e Vr ies

Univers i ty o f Twen te - Eng inee r i ng Techno logy : A n d r é D o r é e

I N F O & C O N T A C T L i g h t h o u s e P ro j ec t s 2 0 1 6 Bio Based B r igde : Ri jk B l o k - r .b lok@tue.nl

CAST F o r m w o r k Systems: M a r c e l B i l o w - m . b i l o w @ t u d e l f t . n l

Convec t i ve C o n c r e t e : D e n n i s d e W i t t e - d . dew i t t e@tude l f t . n l

D o u b l e C u r v e d 3 D C o n c r e t e Pr in t ing : Roe l S c h i p p e r - h . r . s c h i p p e r @ t u d e l f t . n l F ib rous Smar t Mater ia ls : N i m i s h B i lo r ia - n .m.b i lo r ia@tude l f t .n l

O p t i m i s i n g 3 D C o n c r e t e Pr in t ing ; J e r o e n C o e n d e r s - j e r o e n c o e n d e r s @ w h i t e - l i o n e s s . c o m Publ ic Space f o r Refugees : J u l i e t t e B e k k e r i n g - j . d . b e k k e r i n g @ t u e . n l

Resorat ive Glass: Fa id ra O i k o n o m o p o u l o u - f . o i k o n o m o p o u l o u @ t u d e l f t . nl

Smar t Sensors in Aspha l t : S e i r g e i M i l l e r - s . r .mi l ler@utwente.n l

Solar Bikes - User A c c e p t a n c e : Pau l i ne v a n d e r B e r g — p .e .w.v .d .berg@tue.n l

S o u n d A b s o r b i n g Glass: M a r t i n T e n p r e r i k - m . j . t e n p i e r i k @ t u d e l f t . n l S P O N G 3 D ; M i c h e l a Tu r i n - m. tur r in@tude l f t .n t

Spy ing t h e U n d e r g r o u n d : L e o n o l d e Scho l tenhu is - l . l .o ldescho l t6nhu is@utwente .n l Unleash t h e Bu i ld ing Bots : A a n t v a n d e r Z e e - a.v.d.zee@tue,ni

I N F O & C O N T A C T P D E n g P ro jec t s

D e Reus van Sch immer t : K o n s t a n t i n o s Tzanakak i s - k. tzanakakis@tue.nl

Industr ia l Symbios is Sof tware : I m m a n u e l G e e s i n g - i . j .a .k.geesing@tue.nl

Transit ion t owa rds D C Mic ro Gr ids : Evi P l o u m p i d o u - e . p l o u m p i d o u @ t u e . n l

PUBLICATION

Ed i t i ng & g raph i c d e s i g n : bu reaubakke r - S i e b e B a k k e r & El ise B u i t e r

Images : bureaubakker , c reat ive p ro jec ts (P; 5, 6, 1 1 , 12, 18, 2 0 , 27 , 28 , 30 , 32 , 34 , 36 , 38 , 39), pa r t i c i pa t i ng researchers

© 2 0 1 7 4TU,Bouw

DOUBLE CURVED CONCRETE PRINTING LHP2016

It is no s e c r e t that there have b e e n s o m e great a d v a n c e s in the realm of concre te addi t ive manufactur ing . However , one of the major d r a w b a c k s of this fabr icat ion t e c h n i q u e is that the e l e m e n t s must be se l f -suppor t ing dur ing pr int ing. Whi le m o s t o ther addi t ive manufactur ing mater ia ls can o v e r c o m e this by using a s e c o n d a r y pr inted s u p p o r t s t ructure , a l ternat ive s t ra teg ies have to b e d e v e l o p e d for mater ia ls such as c o n c r e t e .

This 4 T U pro ject e x p l o r e s the possibi l i t ies of combin ing concre te addi t ive manufactur ing wi th a t e m p o r a r y s u p p o r t sur face . By print ing on a f ree- form sur face , more intr icate g e o m e t r i e s can b e rea l i zed . A n u m b e r of potent ia l appl icat ions have b e e n out l ined, h o w e v e r the principle focus is combin ing c o n c r e t e addi t ive manufactur ing a n d cas t ing . T h e e n d result is a part ia l ly-pr inted pavil ion using a comple te ly digital design- to- fabr icat ion workf low.

mm

A l t h o u g h add i t i ve manu fac tu r i ng (AM) is a

fabr ica t ion t e c h n i q u e wh ich has b e e n a round fo r

t h e past 20 years or so , it is on ly n o w tha t w e are

s tar t ing t o see its app l i ca t ions e m e r g e in to t h e

bu i l t e n v i r o n m e n t . Wh i l s t meta ls , plast ics a n d

Concrete that shows great potential for large-scale additive manufacturing. o the r c o m p o s i t e mater ia ls are also b e i n g e x p l o r e d

fo r t he i r use in t h e Bui l t env i r onmen t , it is concre te

t ha t shows g rea t po ten t i a l f o r large-scale add i t i ve

manu fac tu r i ng . Conc re te Pr int ing t echn iques

a l ready a l l ow fo r t h e rap id fab r i ca t ion o f la rge-

scale st ructures w i t h m in ima l mater ia l was te , as

a l ready e x h i b i t e d by W insun and t h e fab r i ca t ion o f

1,100 S q m A p a r t m e n t s in J iangsu , Ch ina .

Wh i l s t th is d o e s i n d e e d a l low fo r t h e rap id

fab r i ca t ion o f conc re te s t ructures, mos t e lemen ts

p r i n t e d rema in as 2 .5D rather than 3 D . This is

d u e t o t h e fac t t h a t e x t r u d e d mater ia l mus t b e

se l f - suppor t i ng d u r i n g p r i n t i ng in o rde r t o avo id

co l lapse, i m p o s i n g s o m e w h a t o f a geome t r i ca l

res t r ic t ion. M o s t o t h e r p r i n t i ng mater ia ls can

o v e r c o m e th is by p r i n t i ng a t e m p o r a r y s u p p o r t

s t ruc ture , h o w e v e r th is is n o t t h e case w i t h f l u id

mater ia ls such as conc re te . Ins tead , a t e m p o r a r y

surface is p r o p o s e d as a means o f s u p p o r t t o

p r i n t e d conc re te .

The a d a p t a b l e m o u l d d e v e l o p e d at TU De l f t

served as a means t o p r o v i d e such a surface.

Cons is t ing o f a s i l icone surface c o n n e c t e d t o a

b e d o f ad jus tab le p ins , d o u b l e - c u r v e d surfaces

can b e p r o d u c e d in a s imi lar fash ion t o m i l l ed

surfaces. The ma in d i f fe rence b e i n g t ha t no

mater ia l was te is g e n e r a t e d since new surfaces are

d e f i n e d by ad jus t ing t h e p i n - b e d . Prior t o t h e 4TU

Project , th is sys tem was used fo r cast ing f r ee - f o rm

conc re te panels . T h e c o m b i n a t i o n 3 D concre te

p r in t i ng a n d an a d a p t a b l e m o u l d resu l ted in a

hyb r id manu fac tu r i ng t e c h n i q u e cons is t ing o f t w o

c o m p l i m e n t a r y fabr ica t ion t echn iques .

Three Potent ia l areas o f research were iden t i f i ed

t h r o u g h this c o m b i n a t i o n . Firstly, t h e po ten t ia l

f o r fu l l y -p r in ted conc re te panels . For th is . It is

p r o p o s e d t o use d i f fe rent ia l g r o w t h a lgo r i t hms

t o gene ra te p r in t paths over any g iven surface.

The s e c o n d po ten t i a l i den t i f i ed was t h e p r in t i ng

o f st ructural r ibs f o l l o w i n g stress-l ines t o p rov ide

re in fo rcemen t t o panels . However , t h e chosen

t h e m e was a c o m b i n a t i o n o f 3 D Pr int ing and

cast ing concre te . In th is , c o m p l e x g e o m e t r i e s

are d e f i n e d by p r in t i ng a b o u n d a r y in to wh ich

conc re te is cast. The a d v a n t a g e t o th is app roach

is t h a t c o m p l e x , f ree - fo rm conc re te panels can

b e real ized w i t h o u t t h e n e e d fo r c o m p l i c a t e d

m o u l d i n g systems.

Complex geometries are defined by printing a boundary into which concrete is cast.

Design Overview In o r d e r t o s tudy t h e p r o p o s e d manu fac tu r ing

c o n c e p t , a shell s t ruc ture cons is t ing o f c o m p l e x

in te r lock ing g e o m e t r y vyas d e s i g n e d and p r i n t ed .

The basic p r inc ip le o f real iz ing the des ign consists

o f f i rst c reat ing a d ig i ta l m o d e l o f t h e s t ructure

us ing paramet r i c des ign too ls . Each ind iv idua l

pane l is t h e n d ig i ta l l y o r i en ted o n t o an adap tab le

m o u l d and G - c o d e is g e n e r a t e d by d i v i d ing

spl ines t ha t de f i ne t h e pe r ime te r o f t h e ob jec t .

O n c e t h e physical m o u l d is ad jus ted t o match t h e

d ig i ta l m o u l d , t h e G c o d e is sent t o t h e p r in te r a n d

t h e g e o m e t r y is p r i n t e d . Finally, concre'te is cast

in to t he p r i n ted shape and left t o cure f o r 24 hours

af ter wh i ch it is d e m o u l d e d .

printing on non-planar surfaces

DESIGN VARIABLES AND CONSTRAINTS

PHYSICAL LIMITATIONS OF ADAPTABLE MOULD AND

PRINTER [END HAS THICKNESS]

m a x i m u m m a x i m u m

INPUT RESULTS CURVATURE

INPUT RESULTS PANELLING

printing angle curvature

Fornn-f inding process: unde rs tand ing t h e l im i ta t ions

FINAL FORM

: ;

DIGITAL MODEL OF GEOMETRY DEFINED USING RHINO

/GRASSHOPPER

IGEOMETRY ORIENTED ONTO; DIGITAL MODEL OF ADAPT­

ABLE MOULD.

PHYSICAL MOULD ADJUSTED TO MATCH

DIGITAL MODEL

GCODE GENERATED USING GRASSHOPPER

PRINTING EDGE ONTO PHYSICAL MOULD

CONCRETE IS CAST INTO PRINTED BORDER USING

USUAL TECHNIQUE

Produc t c o n c e p t

Fabrication Process Both the 3 D Pr inter a n d a d a p t a b l e m o u l d have

the i r o w n set o f physical l im i ta t ions. Thus, a

n u m b e r o f var iab les a n d constra in ts we re set

by s tudy ing t h e t w o t e c h n o l o g i e s . Firstly, t h e

m a x i m u m s lope ang le o n wh ich conc re te can

be p r i n ted was f o u n d t o be 40 Degrees , af ter

wh ich mater ia l had a t e n d e n c y t o curl u p a n d

d is tor t . This va lue was used t o l imi t t h e m a x i m u m

curvature o f t h e f o r m - f o u n d shell s t ruc ture . D u e

t o t h e pr inter 's incapab i l i t y t o p r in t r i gh t ang les ,

a m i n i m u m t u r n i n g radius was also d e t e r m i n e d

and was used t o gene ra te t h e tesse l la t ions f o r

p r i n ted geome t r y . The e n d result is a 2.5 m x.2.5

m shell w i t h a m a x i m u m s lope o f 35 deg rees a n d

m i n i m u m t u r n i n g radius o f 150 m m , cons is t ing o f a

to ta l o f 9 Pr in t -And-Cast panels .

The end result is a 2.5m x 2.5m shell consisting of a total of 9 Print-And-Cast panels.

In o rde r t o have a des ign process wh ich consists

o f a s ing le f i le f r o m des ign t o fab r i ca t i on , a

cus tom g - c o d e g e n e r a t o r was c rea ted us ing

Grasshopper 3 D . This was also necessary because

sl ic ing t echn iques used in t rad i t i ona l add i t i ve

manu fac tu r ing c o u l d no t b e used since a later-wise

app roach was n o t used . Ins tead, t h e g e o m e t r y is

d e f i n e d as a sp l ine and is d i v i d e d in to a n u m b e r

o f po in ts d e p e n d i n g on curvature o f t h e curve.

These po in ts are t h e n expressed in t e r m s o f t he i r

relat ive co -o rd ina tes and c o m m u n i c a t e d w i t h

t h e Pr inter A n add i t i ona l b e s p o k e scr ip t was

g e n e r a t e d t o take in to accoun t col l is ions o f t h e

Printer Nozz le w i th t h e Surface. This was requ i red

because p r i n t i ng was no t d o n e pe rpend i cu la r t o

t he surface m e a n i n g t h a t t h e physical nozzle had

a t e n d e n c y t o co l l ide w i th s teep surfaces. The

way th is was co r rec ted was by d e t e r m i n i n g t h e

in tersect ion b e t w e e n t h e nozzle a n d surface at

every co -o rd ina te a n d ra is ing t h e p o i n t such tha t

no in tersect ions occu r red . The co r rec ted p r in t pa th

is t hen d e f i n e d by i n t e rpo la t i ng t h e ra ised po in t s

wh ich is t h e n c o n v e r t e d in to G - C o d e .

Final Structure The f inal s t ructure is p r i n t e d in a s ing le p r in t pass

tak ing app r ox i m a te l y 20 m inu tes t o c o m p l e t e as

shown in t h e i m a g e be low. A f t e r t h e ind iv idua l

panels are p r i n t e d , plast ic izer is m i x e d in w i th

p r i n t e d conc re te and cast ins ide t h e pane ls . These

are lef t t o cure f o r 24 hours a n d d e m o u l d e d as an

inver ted shell s t ruc ture . Th is is later t e m p o r a r i l y

p r o p p e d u p a n d he ld t o g e t h e r t h r o u g h m o r t a r

j o in ts .

Challenges and conclusions The p ro jec t was l im i ted t o a re lat ively smal l 2.5 m

X 2.5 m shell s t ruc ture a n d t h e g e o m e t r i e s p r i n t e d

we re k e p t relat ively s imp le so as t o focus o n

re f in ing t h e des ign process. However , g i ven t h a t

t h e physical const ra in ts o f t h e p r i n t i ng process

have b e e n es tab l i shed it is easi ly i m a g i n a b l e t h a t

scalabi l i ty a n d increase o f g e o m e t r i c a l c o m p l e x i t y

can be ach ieved if b o u n d a r y cond i t i ons are

ma in ta i ned . Moreover , t h e p ro jec t f o c u s e d o n

c o m b i n i n g p r i n t i ng a n d cas t ing , h o w e v e r o the r

d i rec t ions such as g e n e r a t i n g p r in t pa ths wh ich

f o l l o w stress-l ines c o u l d serve as fu tu re areas o f

research us ing t h e same basic des ign process.

De l f t Univers i ty o f T e c h n o l o g y

dr. i r Roel Sch ipper , C h r i s B o r g C o s t a n z i MSc.

E indhoven Univers i ty o f Techno iogy

dr. i r F r e e k B o s , Z e e s h a n A h m e d M S c ,

Rob Wol fs M S c