Manufacturing integrated building components using digital hybrid Concrete Printing (HCP) technology

Lead Research Organisation: Loughborough University
Department Name: Architecture, Building and Civil Eng

Abstract

The Government's Industrial Strategy highlights the need for the construction industry to embrace digitally-driven, automated manufacturing if it is going to deliver the planned infrastructure development, building and renovation of the built environment. The group funded through this award understands this need and envisages an industry that routinely deploys digitally-driven, off-site-manufacturing technologies to deliver customised and unique precision components to enable the rapid, just-in-time assembly of the built environment. Seamless digital workflow and accurate process simulation will reduce the time from design to product from weeks to hours, delivering buildings faster. It will facilitate the optimisation of components, removing unwanted material (reduced resource use and embedded CO2), designing out interfaces and reducing assembly time and complexity, both during installation and at end of life.

3D Concrete Printing (3DCP) is a digitally-driven, off-site manufacturing technology that is establishing itself worldwide as a viable manufacturing process, but its potential beyond aesthetic objects is fundamentally limited by the manufacturing tolerances achievable. The work undertaken by this group will develop the next generation, Hybrid Concrete Printing (or HCP), technology that uses 3DCP to create a near-net-shape (an object slightly larger than the desired object) and then uses subtractive process (cutting, milling and drilling) to remove a small amount of material to create the net-shape - the desired object to sub-millimetre precision. HCP technology will enable the intelligent integration of building performance and energy production and storage technologies, freed from traditional constraints on form and finish.

This will unlock the potential for accurate interfaces and assemblies and, hence, open the gateway for a revolution in design and manufacture of buildings and the wider built environment. The team will develop research that answers three central goals of the Industrial Strategy Challenge Fund's Transforming Construction initiative:

- Designing and managing buildings: We will develop and promote new design tools and design capabilities for UK design practise that will create globally marketable expertise;
- Constructing quality buildings: HCP, a digitally-driven off-site manufacturing technology, will realise greater precision in manufacture than is currently possible, enabling repeatable, high quality components to be manufactured with a much shorter lead-time; and,
- Powering buildings: The technology gives the designer close control of surface finish and component geometry, enabling them to add value through function and to design in order to integrate other active components as part of automated assembly.

Planned Impact

The project will create new, world-leading knowledge and commercial impact across our complete supply chain initiative we call 'MADE': Materials, Automation, Design and End user.

Materials: New products developed and marketed by UK-based Synthomer are an expected outcome of the work based on the admixture technology to precisely adjust rheology for variations in batched material. These are expected to create jobs and increased turnover from new markets and export opportunities.

Automation: The digital work flow for creating tool paths during printing and for subsequent subtractive operations will inform future developments of the UK-based Autodesk Powermill software capability, building on their success with the hybrid welding process used to create WAAMpeller. It will also open up new market opportunities for creative design, freed from traditional constraints on form and function.

Design: The design methods will be embedded in design software developed within UK-based Cundall, and Foster and Partners, to enable them to design for manufacture using 3DCP and HCP. This capability places both organisations ready to deliver HCP as a solution for clients, creating a pull for the technology and increasing market share.

End user: Our end-user, Urba-Style, and our startup initiative, Concrenetics, provide an established route to market for the technology. Uptake will create jobs across the sector.

Wider industry engagement:

An industry focused case study report will be written, making the case for the commercial viability of HCP. This will be disseminated through dedicated industry workshops and our experienced dissemination partners, e.g. the BRE, to promote the technology, attract investment, engage potential customers and other organisations interested in becoming part of the technology supply chain.

A publicly accessible video story book will be produced in the same style as those recently undertaken by Autodesk for their WAAMpeller and Simplexity projects. These will be made in conjunction with partners to showcase the technology to lever third party engagement and raise the investment required to generate more rapid uptake and penetration of the technology.

Towards the end of the project we will prepare a stand at the 2021 UK Concrete Show (+180 exhibitors) to showcase the project outcomes to the wider UK and international concrete industrialists and public through the stand and technical lectures.

Publications

10 25 50

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Buswell R. (2022) Preface in RILEM Bookseries

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Kinnell P. (2021) Precision manufacture of concrete parts using integrated robotic 3D printing and milling in Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

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Buswell R (2022) CCR digital concrete 2022 SI: Editorial in Cement and Concrete Research

 
Description This work has demonstrated an order of magnitude improvement in the accuracy and precision of components manufactured using 3-D concrete printing. This is significant, as it opens up the potential for far greater products and the integration with other construction systems.
Exploitation Route We developed a new approach to benchmark testing geometric conformity of large-scale 3-D concrete printing processes. This is the first of its kind in the world, and we are currently exploring how to engage other research labs internationally in full-scale trials using our test procedure, that will be published in the next month or so.

Also the technology developed has led to the design and manufacture of a full-scale bust up canopy system, manufactured with hybrid concrete printing that allows assembly and disassembly, and is fully integrated with building services. Is the first of its kind in the world, to be completed in 2023
Sectors Construction

Digital/Communication/Information Technologies (including Software)

Manufacturing

including Industrial Biotechology

 
Description This work has been carried out in parallel with a start-up initiative based in Belgium, where we were trying to exploit the technology. This has led to one installation in Belgium, and another in Dubai. Now 4 systems have been sold wold wide and another 3 on order. The systems installed in Belgian and now in production I finishing Parts. we have design and in the process of manufacturing I will first full-scale demonstrated to be installed currently on the Univritycampus in 2023.
Sector Construction
Impact Types Economic

 
Description Keynote presentation at the ROYAL Irish Academy on the future of education to support modern method of construction
Geographic Reach Europe 
Policy Influence Type Contribution to a national consultation/review
 
Description First Time Concrete: Integrated digital models for right-first-time 3D concrete printing and milling
Amount £1,019,148 (GBP)
Funding ID EP/X02430X/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 07/2023 
End 10/2026
 
Title 3DCP Bench mater test geometry 
Description This is the first geometry of its kind designed to test and benchmark manufacturing accuracy on large-scale three-dimensional printing machines, to enable cross-platform verification and comparisons and manufacturing precision . 
Type Of Material Computer model/algorithm 
Year Produced 2022 
Provided To Others? Yes  
Impact 313 views 201 downloads 
URL https://repository.lboro.ac.uk/articles/online_resource/CAD_model_of_a_standardised_test_geometry_fo...
 
Title 3DCP GD and T geometry 
Description Three dimensional solid model of a test geometry used to measure and verify printing accuracy. 
Type Of Material Computer model/algorithm 
Year Produced 2020 
Provided To Others? Yes  
Impact 1022 views 174 downloads no citations as yet 
URL https://repository.lboro.ac.uk/articles/online_resource/Test_part_CAD_model_for_GD_T_in_3D_Concrete_...
 
Description HCP partners 
Organisation Autodesk
Country United States 
Sector Private 
PI Contribution Insight in to the latest technology developments Training for a PhD in structures and knowledge transfer for Cundall Technology turner into industry
Collaborator Contribution Design insights Materials insights Manufacturing and market insights Technology insights
Impact N/A
Start Year 2019
 
Description HCP partners 
Organisation Concrenetics
Country Belgium 
Sector Private 
PI Contribution Insight in to the latest technology developments Training for a PhD in structures and knowledge transfer for Cundall Technology turner into industry
Collaborator Contribution Design insights Materials insights Manufacturing and market insights Technology insights
Impact N/A
Start Year 2019
 
Description HCP partners 
Organisation Cundall
Country United Kingdom 
Sector Private 
PI Contribution Insight in to the latest technology developments Training for a PhD in structures and knowledge transfer for Cundall Technology turner into industry
Collaborator Contribution Design insights Materials insights Manufacturing and market insights Technology insights
Impact N/A
Start Year 2019
 
Description HCP partners 
Organisation Foster and Partners
Country United Kingdom 
Sector Private 
PI Contribution Insight in to the latest technology developments Training for a PhD in structures and knowledge transfer for Cundall Technology turner into industry
Collaborator Contribution Design insights Materials insights Manufacturing and market insights Technology insights
Impact N/A
Start Year 2019
 
Description HCP partners 
Organisation Synthomer plc
Country United Kingdom 
Sector Private 
PI Contribution Insight in to the latest technology developments Training for a PhD in structures and knowledge transfer for Cundall Technology turner into industry
Collaborator Contribution Design insights Materials insights Manufacturing and market insights Technology insights
Impact N/A
Start Year 2019
 
Description HCP partners 
Organisation Urbastyle
Country Belgium 
Sector Private 
PI Contribution Insight in to the latest technology developments Training for a PhD in structures and knowledge transfer for Cundall Technology turner into industry
Collaborator Contribution Design insights Materials insights Manufacturing and market insights Technology insights
Impact N/A
Start Year 2019
 
Description 3DCP House building Hackathon 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Study participants or study members
Results and Impact Part of the 3-D printing student competition organised by Lafarge, presentation rose awareness and help educate student teams from around the world. The competition had about 14 teams from International backgrounds including the US Australia Singapore and across Europe. Active promotion of the technology the work that's undertaken in the UK to the next generation of research and technology enthusiasts in the field.
Year(s) Of Engagement Activity 2020
URL https://www.lafargeholcim.com/first-3d-printing-hackathon-witteveen-bos
 
Description Attendance at Futurebuild 2020 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Manned a stand for 3DCP with the ISCF area and was part of the Concrete Society stand: Researchers presented the work and engaged industry.
Year(s) Of Engagement Activity 2020
URL https://www.futurebuild.co.uk
 
Description British precast week presentation 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact This was a presentation engagement activity with industry through British Precast. This was informing and engaging the industry and potential manufacturing organisations with the potential of the new technology. As part of this we undertook marketing poll to gauge industrial awareness and the potential drivers for the technology from the manufacturing perspective. The insights gained were used to support arguments to take the technology forward and to improve its impact.
Year(s) Of Engagement Activity 2020
URL https://www.precastweek.org/speakers
 
Description Keynote DC2020 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact Keynote presentation as a conference on the classification system for large-scale additive manufacturing.

This was one of the principal outputs of the Rylan technical committee working group which I lead and presented at the conference.

This document aligns the processes that are on the development with the current iso standard practice in manufacturing, I was the first time the agreement across the community for the terminology and classification of the systems was achieved.
Year(s) Of Engagement Activity 2020
 
Description Keynote SPIE 2021 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact Promoting through the concrete printing technology with international platform.
Year(s) Of Engagement Activity 2021
 
Description Keynote at DC2022 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact Invited paper DC 2022: on assessment of geometric quality assessment for 3DCP - this paper was a seminal work introducing the notion of cross platform verification and quality assurance assessment for through the concrete pretty processes. This is a leading work in the field and one that will grow in the future.
Year(s) Of Engagement Activity 2022
 
Description Opening Keynote DC2022 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact Opening Keynote for digital concrete 2022, this paper was the third in a series of papers that defined the company and provide a research roadmap for the technology. This is the first paper that is a temperature assessed technology readiness level of 3DCP
Year(s) Of Engagement Activity 2022
 
Description Opening Keynote at the Royal Irish Academy 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Policymakers/politicians
Results and Impact This was an invited a presentation to debate the need for higher education to support the move towards digital construction industry and to support modern methods of construction. Organised by the Lord Academy with the principal aim of influencing policy in decision-making in Ireland.
Year(s) Of Engagement Activity 2022
 
Description Participation in RILEM TCs relating to concrete printing 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact This activity is a technical working great that engages academics and industry for pre-standardisation work. The first technical committee run from 2016 to 2020, and there are now two other technical committees that I have a 4 to 5 year lifespan that we attend probably twice a year.

Estate of your report was the outcome of the first, and we contributed to leading a chapter and introducing a new classification framework that the whole community globally can use.
Year(s) Of Engagement Activity 2019,2020,2021,2022,2023
 
Description Presentation at International DBV/DAfStb/RILEM Colloquium on Digital Fabrication with Concrete 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Presentation on 3DCP moving 3DCP from the lab to the commercial environment
Year(s) Of Engagement Activity 2020
 
Description RILEM/ISCF International workshop on advances in 3D concrete printing and construction automation 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact For half a day, ten speakers from five countries will present updates from from the recently announced industrial strategy Core Innovation Hub and Research Leaders initiatives in the UK and present the latest large scale 3DCP case studies from across Europe.

Open forum for technology updates and open academic/industrial discussion on the development of a new classification approach for the processes used in the Digital Fabrication with Concrete (which includes 3DCP)
Year(s) Of Engagement Activity 2019
 
Description UK Concrete Society presentation 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact And invited presentation as part of concrete society, raising awareness of the research and the technology and the potential to influence construction. There were 80 academics industrialists and practitioners taking part and engaging and interaction questions followed presentation.
Year(s) Of Engagement Activity 2020
URL https://eps.leeds.ac.uk/faculty-engineering-physical-sciences/news/article/5689/the-adam-neville-pri...