640 research outputs found

    Extrusion-based additive manufacturing of concrete products. Revolutionizing and remodeling the construction industry

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    Additive manufacturing is one of the main topics of the fourth industrial revolution; defined as Industry 4.0. This technology offers several advantages related to the construction and architectural sectors; such as economic; environmental; social; and engineering benefits. The usage of concrete in additive technologies allows the development of innovative applications and complexity design in the world of construction such as buildings; housing modules; bridges; and urban and domestic furniture elements. The aim of this review was to show in detail a general panoramic of extrusion-based additive processes in the construction sector; the main advantages of using additive manufacturing with the respect to traditional manufacturing; the fundamental requirements of 3D printable material (fresh and hardened properties), and state-of-the-art aesthetic and architectural projects with functional properties

    From 3D Models to 3D Prints: an Overview of the Processing Pipeline

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    Due to the wide diffusion of 3D printing technologies, geometric algorithms for Additive Manufacturing are being invented at an impressive speed. Each single step, in particular along the Process Planning pipeline, can now count on dozens of methods that prepare the 3D model for fabrication, while analysing and optimizing geometry and machine instructions for various objectives. This report provides a classification of this huge state of the art, and elicits the relation between each single algorithm and a list of desirable objectives during Process Planning. The objectives themselves are listed and discussed, along with possible needs for tradeoffs. Additive Manufacturing technologies are broadly categorized to explicitly relate classes of devices and supported features. Finally, this report offers an analysis of the state of the art while discussing open and challenging problems from both an academic and an industrial perspective.Comment: European Union (EU); Horizon 2020; H2020-FoF-2015; RIA - Research and Innovation action; Grant agreement N. 68044

    Topological optimization of structures produced through 3D printing of fiber reinforced cementitious materials

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    Dissertação de mestrado integrado em Engenharia CivilTopology optimization can play an important role in the Architecture, Engineering and Construction (AEC) sector. This technology along with digital manufacturing can be a game changer in the future of civil construction, allowing to build, in a short time period, lighter constructions with very geometry complexity but keeping the same of even better structural functioning. These optimized structures when coupled with a material with high capacity efforts redistribution, e.g. fibre reinforced cementitious material (FRC), can partially or totally substitute the conventional reinforcement, consequently less raw material is use, contributing for a better sustainable development. Following this idea, this dissertation will focus on study topology optimization processes along with the use of FRC materials. Initially a comparison between some topology optimization software’s will be carried out, in order to proper evaluate to most suitable for the realization of the present work. In a second stage, considering only the linear behavior of the material, different topology optimization analyses will be done. These analyses will be based on the geometry and the intended structural application (support and load conditions), in addition to the optimization goal (design variable and constraint). This part aims to assess the influence of height / length ratio (H/L ratio) of the beam, in the optimization outcome. After that, a study of the influence of reinforcement amount in the optimization will be done. Afterwards, some finite element analysis (FEA) for one of the optimized structures will be performed and assessed using distinct approaches for obtaining the tensile stress – strain relationship, namely by adopting the ultimate limit state (USL) and service limit state (SLS) tensile diagrams according to the recommendations presented in FIB Model Code 2010. These simulations will serve to evaluate the nonlinear behavior of the FRC structure. For this study six FRC with different strength classes were considered. Finally, an optimized structural element obtained through the FEA was sliced for 3D printing and the influence of the nozzle dimensions, i.e. printing resolution was checked.A otimização da topologia pode desempenhar um papel importante no setor de Arquitetura, Engenharia e Construção (AEC). Esta tecnologia aliada à manufatura digital pode completamente revolucionar o futuro da construção civil, permitindo construir, num curto espaço de tempo, construções mais leves, mas mantendo o mesmo ou ainda melhor funcionamento estrutural. Estas estruturas otimizadas quando conjugadas a um material com alta capacidade de redistribuição de esforços, por ex. materiais cimentícios reforçado com fibras (FRC), pode substituir parcial ou totalmente o reforço convencional, onde consequentemente menos matéria-prima será utilizada, contribuindo-se assim, para um melhor desenvolvimento sustentável. Seguindo essa ideia, esta dissertação terá como foco estudar processos de otimização de topológica juntamente com o uso de materiais FRC. Inicialmente será realizada uma comparação entre alguns softwares de otimização de topológica, a fim de avaliar adequadamente o mais adequado para a realização do presente trabalho. Em uma segunda etapa, considerando apenas o comportamento linear do material, serão realizados diferentes processos de otimização topológica. Essas otimizações serão baseadas na geometria e na aplicação estrutural pretendida e no objetivo da otimização. Esta parte visa avaliar a influencia da relação altura/comprimento da viga (relação H/L), no resultado da otimização. Posteriormente, algumas análises de elementos finitos (FEM) para uma das estruturas otimizadas serão realizadas e avaliadas usando duas abordagens distintas para a obtenção da relação tensão de tração – deformação, uma para estado limite último (ELU) e estado limite de serviço (ELS), seguindo as recomendações presentes no FIB Model Code 2010. Estas simulações servirão para avaliar o comportamento não linear da estrutura de FRC. Para este estudo foram considerados seis FRC com diferentes classes de força. Finalmente, para um elemento estrutural otimizado anteriormente, foi realizada uma simulação de impressão 3D, de modo a estudar a influencia do tamanho do bico de impressão, ou seja, a resolução de impressão foi verificada

    Stress-oriented structural optimization for frame structures

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    To fabricate a virtual shape into the real world, the physical strength of the shape is an important consideration. We introduce a framework to consider both the strength and complexity of 3D frame structures. The key to the framework is a stress-oriented analysis and a semi-continuous condition in the shape representation that can both strengthen and simplify a structure at the same time. We formulate a novel semi-continuous optimization and present an elegant method to solve this optimization. We also extend our framework to general solid shapes by considering them as skeletal structures with non-uniform beams. We demonstrate our approach with applications such as topology simplification and structural strengthening

    Effect of raw materials on the performance of 3D printing geopolymer: A review

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    Traditional construction materials such as cement products release a significant amount of carbon dioxide during their preparation and usage, negatively impacting on the environment. In contrast, 3D printing (3DP) with geopolymer materials utilises renewable and low-carbon emission raw materials. It also exhibits characteristics such as energy efficiency and resource-efficient utilisation, contributing to reduction in carbon emissions and an improvement in sustainability. Therefore, the development of 3DP geopolymer holds great significance. This paper provides a comprehensive review of 3DP geopolymer systems, examining the effect of raw materials on processability, including flowability and thixotropy, and microstructure. The study also delves into sustainability and environmental impact. The evaluation highlights the crucial role of silicon, aluminium, and calcium content in the silicate raw material, influencing the gel structure and microstructural development of the geopolymer. Aluminium promotes reaction rate, increases reaction degree, and aids in product formation. Silicon enhances the mechanical properties of geopolymer, while calcium facilitates the formation and stability of the three-dimensional network structure, further improving material strength and stability. Moreover, the reactivity of raw materials is a key factor affecting interlayer bonding and interface mechanical properties. Finally, considering sustainability, the selection of raw materials is crucial in reducing carbon emissions, energy consumption, and costs. Compared to Portland cement, 3DP geopolymer material demonstrate lower carbon emissions, energy consumption, and costs, thus making it a sustainable material

    Processes and materials used for direct writing technologies:A review

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    Direct Writing (DW), also known as Robocasting, is an extrusion-based layer-by-layer manufacturing technique suitable for manufacturing complex geometries. Different types of materials such as metals, composites, ceramics, biomaterials, and shape memory alloys can be used for DW. The simplicity and cost-efficiency of DW makes it convenient for different applications, from biomedical to optics. Recent studies on DW show a tendency towards the development of new materials and applications. This represents the necessity of a deep understanding of the principles and parameters of each technique, material, and process challenge. This review highlights the principles of many DW techniques, the recent advancements in material development, applications, process parameters, and challenges in each DW process. Since the quality of the printed parts by DW highly depend on the material extrusion, the focus of this review is mainly on the ceramic extrusion process and its challenges from rheological and material development point of view. This review delivers an insight into DW processes and the challenges to overcome for development of new materials and applications. The main objective of the review is to deliver necessary information for non-specialist and interdisciplinary researchers

    The exploitation of polymer based nanocomposites for additive manufacturing: a prospective review

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    Additive manufacturing (AM) is a well-known technology for making real three dimensional objects, based on metal, ceramic and plastic material used for various applications. The aim of this review is to explore and offer an insight in to the state of the art polymer based nanocomposites in to additive manufacturing applications. In context to this, the developing efforts and trends in nanocomposites development particularly for additive manufacturing processes were studied and summed up. The scope and limitations of nanocomposites into Stereolithography, selective laser sintering and fused deposition modeling was explored and highlighted. The review highlights widely accepted nanoparticles for range of applications including mechanical, electrical, flame retardance and crossing over into more biological with the use of polymer matrices. Acquisition of functional parts with limitations in regard to printing is highlighted. Overall, the review highlights successes, limitations and opportunities that the union of AM and polymer based nanocomposites can bring to science and technology

    Analysis of 3d Printed Beams and Truss Bridges

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    Fused Deposition Modeling (FDM), a common form of 3d printing, has several key drawbacks that make it difficult to analyze using traditional engineering equations. This paper analyzed traditional engineering models in regards to 3d printed beams in bending and proposes adapted equations. The proposed infill based model accurately predicts the failure point of beams, and is suitable for both direct calculation of beam strength and for comparative analysis with changing part dimensions and printing variables. Additionally, a new system for breaking 3d printed truss bridges is proposed for use in educational settings, which allows quick and simple setup with minimal printing time

    Concrete Structures 23.

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    Sketch2Stress: Sketching with Structural Stress Awareness

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    In the process of product design and digital fabrication, the structural analysis of a designed prototype is a fundamental and essential step. However, such a step is usually invisible or inaccessible to designers at the early sketching phase. This limits the user's ability to consider a shape's physical properties and structural soundness. To bridge this gap, we introduce a novel approach Sketch2Stress that allows users to perform structural analysis of desired objects at the sketching stage. This method takes as input a 2D freehand sketch and one or multiple locations of user-assigned external forces. With the specially-designed two-branch generative-adversarial framework, it automatically predicts a normal map and a corresponding structural stress map distributed over the user-sketched underlying object. In this way, our method empowers designers to easily examine the stress sustained everywhere and identify potential problematic regions of their sketched object. Furthermore, combined with the predicted normal map, users are able to conduct a region-wise structural analysis efficiently by aggregating the stress effects of multiple forces in the same direction. Finally, we demonstrate the effectiveness and practicality of our system with extensive experiments and user studies.Comment: 16 figure
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