Applications of additive manufacturing in the construction industry

Additive Manufacturing (AM) or 3D printing, the process of fabricating components in a layer-wise fashion, has been increasingly applied in industries such as automotives and aerospace. In the 1990s, interest from the construction industry evolved through several experimental applications looking to reduce labor cost, waste material, or create complex shapes that are difficult to build using conventional construction methods. However, the full range of potential applications for construction have not been explored, and the industry’s involvement with AM is still considered at its early stages. As a first step, this thesis provides an extensive literature review of AM as it relates to the construction industry. This research identifies the most significant AM processes, compared to subtractive or formative processes, as well as some technologies and materials being used. A recommendation is given for potential advancements in applications for construction. The thesis also explores the use of typical small-scale material extrusion desktop 3D printers to print and test customized fastener-free connections. The intent of these connection tests is to explore novel ways in which AM technology can be used for structural and non-structural applications using commercial polymers. The connections were inspired by traditional wood joinery and modern proprietary connections. A four-point bending test was used to evaluate their potential structural performance in bending and to identify connection types that could be used for future investigations. Before AM can realize its full potential, interdisciplinary research is still needed to provide new materials, reliable printed parts, and new and repeatable processes. This thesis provides initial steps toward this goal by finding research gaps, identifying research trends in the area, and by exploring initial benefits and limitations for non-structural and structural applications in construction using available small-scale AM technology.Civil, Architectural, and Environmental Engineerin

Fabricate 2020

Fabricate 2020 is the fourth title in the FABRICATE series on the theme of digital fabrication and published in conjunction with a triennial conference (London, April 2020). The book features cutting-edge built projects and work-in-progress from both academia and practice. It brings together pioneers in design and making from across the fields of architecture, construction, engineering, manufacturing, materials technology and computation. Fabricate 2020 includes 32 illustrated articles punctuated by four conversations between world-leading experts from design to engineering, discussing themes such as drawing-to-production, behavioural composites, robotic assembly, and digital craft

Automatic Romaine Heart Harvester

The Romaine Robotics Senior Design Team developed a romaine lettuce heart trimming system in partnership with a Salinas farm to address a growing labor shortage in the agricultural industry that is resulting in crops rotting in the field before they could be harvested. An automated trimmer can alleviate the most time consuming step in the cut-trim-bag harvesting process, increasing the yields of robotic cutters or the speed of existing laborer teams. Leveraging the Partner Farm’s existing trimmer architecture, which consists of a laborer loading lettuce into sprungloaded grippers that are rotated through vision and cutting systems by an indexer, the team redesigned geometry to improve the loading, gripping, and ejection stages of the system. Physical testing, hand calculations, and FEA were performed to understand acceptable grip strengths and cup design, and several wooden mockups were built to explore a new actuating linkage design for the indexer. The team manufactured, assembled, and performed verification testing on a full-size metal motorized prototype that can be incorporated with the Partner Farm’s existing cutting and vision systems. The prototype met all of the established requirements, and the farm has implemented the redesign onto their trimmer. Future work would include designing and implementing vision and cutting systems for the team’s metal prototype

Feasibility of remotely manipulated welding in space. A step in the development of novel joining technologies

In order to establish permanent human presence in space technologies of constructing and repairing space stations and other space structures must be developed. Most construction jobs are performed on earth and the fabricated modules will then be delivered to space by the Space Shuttle. Only limited final assembly jobs, which are primarily mechanical fastening, will be performed on site in space. Such fabrication plans, however, limit the designs of these structures, because each module must fit inside the transport vehicle and must withstand launching stresses which are considerably high. Large-scale utilization of space necessitates more extensive construction work on site. Furthermore, continuous operations of space stations and other structures require maintenance and repairs of structural components as well as of tools and equipment on these space structures. Metal joining technologies, and especially high-quality welding, in space need developing

Automated re-prefabrication system for buildings using robotics

Prefabrication has the advantages of simplicity, speed and economy but has been inflexible to changes in design which is a primary reason behind its limited market share in the construction industry. To tackle this drawback, this study presents a Robotic Prefabrication System (RPS) which employs a new concept called “re-fabrication”: the automatic disassembly of a prefabricated structure and its reconstruction according to a new design. The RPS consists of a software module and a hardware module. First, the software employs the 3D model of a prefabricated structure as input, and returns motor control command output to the hardware. There are two underlying algorithms developed in the software module. First, a novel algorithm automatically compares the old and new models and identifies the components which the two models do not have in common in order to enable disassembly of the original structure and its refabrication into the new design. In addition, an additional novel algorithm computes the optimal refabrication sequence to transform one model into another according to the differences identified. Meanwhile, the hardware module takes the motor control commands as input and executes the appropriate assembly/disassembly operations, and returns the desired refabricated structure in realtime. Validation tests on two lab-scaled prefabricated structures demonstrate that the system successfully generated the desired refabrication sequences and performed all assembly operations with acceptable placement precision

RAMP: a benchmark for evaluating robotic assembly manipulation and planning

We introduce RAMP, an open-source robotics benchmark inspired by real-world industrial assembly tasks. RAMP consists of beams that a robot must assemble into specified goal configurations using pegs as fasteners. As such, it assesses planning and execution capabilities, and poses challenges in perception, reasoning, manipulation, diagnostics, fault recovery, and goal parsing. RAMP has been designed to be accessible and extensible. Parts are either 3D printed or otherwise constructed from materials that are readily obtainable. The design of parts and detailed instructions are publicly available. In order to broaden community engagement, RAMP incorporates fixtures such as April Tags which enable researchers to focus on individual sub-tasks of the assembly challenge if desired. We provide a full digital twin as well as rudimentary baselines to enable rapid progress. Our vision is for RAMP to form the substrate for a community-driven endeavour that evolves as capability matures

Development of a truss joint for robotic assembly of space structures

This report presents the results of a detailed study of mechanical fasteners which were designed to facilitate robotic assembly of structures. Design requirements for robotic structural assembly were developed, taking into account structural properties and overall system design, and four candidate fasteners were designed to meet them. These fasteners were built and evaluated in the laboratory, and the Hammer-Head joint was chosen as superior overall. It had a high reliability of fastening under misalignments of 2.54 mm (0.1 in) and 3 deg, the highest end fixity (2.18), the simplest end effector, an integral capture guide, good visual verification, and the lightest weight (782 g, 1.72 lb). The study found that a good design should incorporate chamfers sliding on chamfers, cylinders sliding on chamfers, and hard surface finishes on sliding surfaces. The study also comments on robot flexibility, sag, hysteresis, thermal expansion, and friction which were observed during the testing