Insights

Construction AM

Building the future, one layer at a time A Warm Welcome

In our penultimate eBook of 2020, we are highlighting a still evolving but disruptive and highly innovative area of additive manufacturing: construction.

The construction segment is a true testament to the versatility and unlimited potential of additive, not only because it is so vastly different from other segments of AM adoption, like consumer goods and aerospace, but because it itself comprises so many different technologies and approaches, from large-format gantry systems, to robotic extrusion printers, to binder jetting machines.

In the following pages we look at many of these different approaches to provide a comprehensive picture of the construction AM segment today. What has been achieved, what is currently happening and, of course, what directions it is going in. One thing that has become abundantly evident in the creation of this eBook is that About though construction AM encompasses many different players with different means, 3dpbm is a leading AM industry media company. 3dpbm most share the same end goal: to provide more sustainable buildings and housing publishes 3D Printing Media Network, a global editorial website through more efficient construction methods and materials. With the construction that has grown to become a trusted and influential resource for industry on the whole looking to a more sustainable future, 3D printing has presented professional additive manufacturing. a possible avenue forward.

Contact Each feature in this eBook—from an in-depth chronology of construction 3D printing, [email protected] to discussions with innovator Enrico Dini, Dutch company CyBe and recent partners www.3dpbm.com Black Buffalo 3D and Lofts to Go—adds another brick to the story of construction AM, illustrating how far the technology has come and just how much further it can go. Cover image: © PERI Group | COBOD Other image credits on Page 44 © 2020 3D Printing Business Media Ltd. All Rights Reserved. Tess Boissonneault Editor in Chief, 3dpbm Composites AM Market Opportunities 2020–2030

Table of Contents The overall composites AM market— including materials, hardware, services and applications—is

6 Analysis forecast to grow from $480 million 15 years on the construction 3D printing elevator: what floor are we on? in 2020 to over $10.6 billion by 2030.

16 Spotlight: Massivit 3D A Massivit acceleration to the adoption of 3D printing in construction

22 Interview: D-Shape Learn more Enrico Dini, Founder

28 Latest Printing a three-story apartment building with COBOD technology

32 Interview: Lofts to Go Jens Rosenthal, Lofts to Go and Peter Cooperman, Black Buffalo 3D

38 Interview: CyBe Berry Hendriks, Founder & CEO In our new 170-page report you’ll find an in-depth analysis of the composites AM

44 Image Credits opportunity, including market positioning of 50 key players along with demand and revenues forecasts for each hardware, materials, software, services, applications and vertical adoption subsegments.

Analysis of leading and emerging companies including: 15 years on the construction 3D printing elevator: what floor are we on?

Construction 3D printing has evolved tremendously over the past 15 years and The construction sector has never seen is gradually becoming accepted in the multi-trillion-dollar construction sector. technological evolution move as rapidly as it has Image: Ricardo Gomez Angel since construction 3D printing emerged. The market is ready, a new industry is coming.

So, it’s been 15 years since the very idea of VRMR, AI, IoT & smart buildings are surging. by Davide Sher construction 3D printing came to be thanks Throughout the world, the foremost to Dr. Behrokh Khoshnevis at the University of construction companies are increasingly Southern California. How far have we come? focusing on innovation and on the digitalization of their business model. This is Actually, a long way. While the overall market set to change and construction 3D printing is still very small within a multi-trillion-dollar may just have evolved enough to be able global construction industry, it is now clear to meet new ConTech demands, not just that a market for construction 3D printing through deposition but also through exists and will continue to expand. In its latest a number of hybrid approaches. In this analysis Global M&A Construction Monitor, Deloitte of the evolution of construction 3D printing points out that all construction technology (ConPrint) we are going to explore the most (ConTech) firms, including those operating in viable solutions for the ConTech challenges of Robotics & 3D printing, Drones & UAVs, AR/ tomorrow, and today.

AM Focus 2020 Construction AM / Analysis 7 Construction AM processes and others) is used to deposit cementitious powder bed fusion technologies can be used digitize the construction segment—and materials in more complex geometric shapes. to produce modular connection systems in developing economies, looking for ways to In this analysis we provide a qualitative This approach— which includes several hybrid complex architectural projects. Standard binder provide low-cost housing to more people. The assessment of the different types of variants—has been used and recorded in 40 jetting and extrusion systems can also be fact that the United States has recorded the construction 3D printing technologies and major applications cases (this figure does used to produce bricks or other modules to be most projects may be somewhat deceiving as technological approaches that have emerged not include dozens of academic experiments assembled in innovative construction projects this list also includes several small experiments over the past 15 years, quantifying the most and studies conducted around the world, but for facades and functional wall structures. conducted by pioneers such as Emerging common types of technologies implemented only the biggest published cases). Robotic Objects. Although it was invented in California, by the number of projects conducted. The deposition can also be used with metals in large-format construction has somewhat Figure 1 most common technological approach is DED (directed energy deposition) and WAAM lagged behind in the US, and has largely been Construction characterized by the use of large format (wire arc additive manufacturing) approaches limited to experiments conducted (proficiently) (2005–2020) mixture extrusion platforms based on a for the production of large structures such as a by the Defense Department. The first very cartesian architecture. pedestrian bridge. Source: 3dpbm Research large construction projects in the US emerged recently, conducted by firms such as ICON, This process was invented by Dr. Koshnevis, The next most common approach, binder 4% 7% Black Buffalo 3D and S-Squared. 5% who gave it the name of . The jetting, is radically different. It is based on a 5% idea at the time was groundbreaking, however powder bed of cement-like material and the The first countries to conduct commercial the basic technology behind it is not overly subsequent application of a binder through an projects around construction 3D printing were 13% complex. For this reason, a number of other inkjet head (hence the name binder jetting). in Asia, with China, Russia and the Middle East ventures emerged based on similar versions of This technological approach is common—and taking leadership roles. The number of recorded 30% this approach. The largest one was founded by gaining more popularity—in the overall additive projects conducted in China— 12 — may also one of Dr. Koshnevis’ students, who brought manufacturing industry to process metals as be somewhat deceiving. Most of these were the idea to the Chinese market with the well as materials. The first person to conducted by one company, WinSun, which WinSun (Yingchuang) brand. With fresh capital envision the use of this process on a very large stands out for the scale of its endeavors— from both the Chinese and Middle Eastern system with cement materials for construction including a river revetment wall measuring 36% governments, WinSun is today the company applications is the Italian Enrico Dini, who used several hundred meters in length. WinSun was that has completed the most and the largest it to print the very first house-like structure, “La among the first to bring its technology to the commercial construction 3D printing projects. casa tutta di un pezzo” (the “entirely one-piece Middle East, where Saudi Arabia and the UAE ther processes 3D Printed Molds Other similar approaches were introduced in house”), in 2010. Because of its powder bed have been some of the most active in adopting 13 inder et 36 F Cartesian xtrusion Russia by AMT Specavia, whose technology approach, binder jetting technology can achieve construction 3D printing. was “adopted” by 3D Printhuset (now COBOD) much more complex geometries but is limited 3 obotic xtrusion Delta xtrusion in Denmark. COBOD technology is now in the by the need to source tailor-made binder Desktop xtrusion Several other players, such as Acciona and rise in the US and in Europe with several large materials. Along with some direct construction CyBe, are also establishing a solid presence construction 3D printing projects now under experiments, binder jetting industrial leader there. Russia was also a pioneer in construction way. voxeljet has shown the proficient use of its Construction AM locations 3D printing, with AMT Specavia and Apis Cor advanced binder jetting technology for the both contending for the record for the first 3D The most direct evolution of large-format production of formworks used in construction. Over the past 15 years a few specific locations printed house in the Russian territory. AMT’s cartesian extrusion construction 3D printing is around the world have emerged as particularly technology, which has been used for a number the multi-axis robotic extrusion approach. In The remaining processes focus on the use receptive to construction 3D printing. At the of other projects in Russia and abroad, was this case, rather than a cartesian architecture of more standard 3D printing technologies same time, the technology has proven to be subsequently adopted by Danish company with the extruder moving on three axes, a to produce smaller, modular construction interesting for both advanced economies— COBOD. Apis Cor has since moved the focus of (such as those from Kuka, Comau components. For example, and metal looking for a way to automate and further its activities to the US.

AM Focus 2020 Construction AM / Analysis 9 Figure 3 After adopting and building upon AMT’s Construction AM trends Construction 3D printing projects (2005–2020) technology, COBOD has become a global leader in construction 3D printing, developing By counting the number of large and Source: 3dpbm Research very large housing projects around Europe significant construction projects undertaken (Denmark, Belgium, Germany) and even over the past 15 years, we can begin to identify 30 partnering with GE on the construction of a growing trend. The number of projects does 25 large bases for wind turbines. not necessarily reflect the size or the value of 25 22 each project, but we can safely state the overall 21 20

In this phase of construction 3D printing’s trend sees strong growth in adoption. We 20 journey, Europe became the largest provider of should also note that 2020 (whether we like it 16 construction AM solutions, through companies or not) is not yet over: even while completing 15 15 based in Spain, France, Italy and especially this eBook, a number of new projects and the Netherlands, which exported systems new companies have emerged in Europe, while also conducting demonstration and Asia and North America. Adding these to the 10 7 commercial projects around Europe. The circle charts would see 2020 registering more overall 5 5 4 is now finally closing with American firms such projects than the previous years. 5 as ICON and Black Buffalo 3D truly embracing construction 3D printing technology to work As with any industry in an embryonal stage, 0 on large development projects. growth is fast but also characterized by an 2005–2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 alternation of rapid peaks and dives. The first significant peak in construction AM was

Figure 2 recorded around 2014. At that time, 3D printing Construction 3D Printing Locations technology was gaining in popularity with the Figure 4 (2005–2020) introduction of the very first low-cost filament YoY growth in the number of construction 3D printing projects (2005–2020) extrusion (sub $1,000) and Source: 3dpbm Source: 3dpbm Research (sub-$5,000) system. As 3D printing overall

gained in popularity and became more 30 China 12 affordable than ever, a number of firms began 220% to leverage the ideas initially put forth by France 8 25 Professor Koshnevis and Dini to undertake the ermany 5 first commercial construction projects. 20 olland 23 114% Several academic institutions—in particular Italy 13 Iaac in Barcelona but also many others all 15 25% thers () 27 over the world—began actively studying 33% technologies and materials. After a short 25% 5% Spain 8 10 period of “disillusionment”, where many early Switzerland 6 movers clashed with limitations in technology, -16% 5 A 5 material quality and software capabilities, -56% the construction 3D printing sectors appears 7 now to be headed for a period of organic and 0 SA 32 continuous growth. 2005–2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

AM Focus 2020 Construction AM / Analysis 11 WASP developed a gigantic delta-style 3D printing system for sustainable on-site construction Image: WASP

2005-2012: The early days industry that exists today. A very high profile project was conducted by DUS Architects in Projects Timeline Amsterdam. The firm collaborated on the Kamer Maker project, a gigantic cartesian The beginning of the construction 3D printing extrusion 3D printer, to produce a house using era can be traced back to 2005, when Professor biodegradable PLA polymer materials. This Koshnevis first introduced the idea of Contour early project failed, although it attracted an Crafting for digitally controlled extrusion of enormous amount of attention, including a cement materials. Shortly thereafter, Italian visit from then US President Obama. Despite entrepreneur and visionary Enrico Dini the failure, that initial experience later evolved presented his own idea for construction 3D into other construction 3D printing projects printing using a powder bed approach, and such as the Aectual 3D printed furniture and built the very first fully 3D printed house (albeit floors. a very tiny house used as proof of concept). Around the same time, US-based engineer Other early pioneers in construction 3D Andrey Rudenko 3D printed a castle in his own printing were architects and professors Ronald backyard. The surprisingly high-quality result Rael and Virginia San Fratello, who founded demonstrated that proficient construction Emerging Objects and presented the idea of 3D printing could be achieved with relatively a 3D printed functional brick produced using low investments. Chinese company WinSun standard binder jetting technology, which took it one step further by demonstrating offers advanced capabilities through complex the ability to 3D print 10 small houses in geometry. Also in this close circle of innovators a 24-hour period. In order to achieve this were researchers from Iaac (Institute for impressive milestone, WinSun abandoned the Advanced Architecture), who continue to idea of on-site automated construction: the push innovation on automated construction company used its large-format construction 2015-2016: Going large received huge amounts of media attention technologies and materials. Finally, Massimo 3D printer to produce wall sections—rapidly and some significant funding but was never Moretti, another Italian pioneer of 3D printing, and cost-effectively—in a facility and then Projects Timeline able to bring a real product to market. Its founded the firm WASP and developed the transported the printed sections to the build vision was carried on by other firms that concept of gigantic delta architecture 3D site. By eliminating the need for formwork, the On the wings of the enthusiasm generated by started smaller in this period and have grown printing for sustainable on-site construction construction process was greatly accelerated. WinSun’s initiatives, which rapidly expanded more gradually. They include CyBe from the using locally sourced materials. to include larger projects in China (including Netherlands, XtreeE from France, Branch During this time—leveraging the rapid a five-story apartment) and new projects in Technologies from the USA and Ai Build expansion of low-cost desktop 3D printing the Middle East (a one-story office building), from the UK. Working with either cement or 2013-2014: Exploration commences systems—a number of collaborative, more companies got into the construction AM , they built successful businesses modular projects also emerged. These were business. In order to address the limitations around the concept of large-format, multi-axis Projects Timeline largely experimental and had no significant of the technology and truly enable on-site robotic extrusion, and continue to grow today. commercial impact, besides for artistic construction, many of them turned to robotic The period between 2013 and 2014 saw the displays. Recently, however, new projects have systems. Sadly, one of the very first firms to This period also saw the first large-size number of experimental projects expand again started to explore the idea of combining introduce the idea of automated construction construction project: an actual pedestrian significantly. Some of these laid the foundation 3D printed elements with traditional materials via robotic extrusion, Cazza, is also one of the bridge for one of Amsterdam’s canals. This for the commercial construction 3D printing to build more complex architectures. few that went out of business. The company project was launched by Joris Laarman Lab

AM Focus 2020 Construction AM / Analysis 13 spinoff MX3D, which uses a robotic DED/ 2018: Laying the foundations WAAM (wire arc additive manufacturing) “In 2020, with new construction system to deposit metal. Another highly Projects Timeline innovative experiment, which has not yet 3D printing projects emerging been translated into a commercial application In 2018, the sprouting construction 3D (other than an advertising campaign for printing industry mostly continued to build almost every week, we can safely Lexus at Milan Design Week a couple of on the foundations that had been laid during years later), came from MIT Media Lab’s the previous year. New housing projects were say that we have a market.” Mediated Matter Research Group. Led by initiated (and largely concluded) in Saudi Neri Oxman, the project focused on cartesian Arabia, Spain, China, Korea and India. extrusion of molten glass. The idea was to eventually integrate this process into cement Some firms also began to diversify their constructions. offering, spinning off into restorations, commenced important construction projects the innovative terracotta hexagon reef tiles 3D bridges, furniture, bus stop shelters, such as an entire community in Mexico. printed by HKU researchers. underwater reefs, army barracks and even WinSun showed that its technology can be As ICON and NASA look to 3D print a moon 2017: Breaking ground toilets for sanitation improvement in remote used to cost-effectively build infrastructure, village, closing the circle and fulfilling the or under-developed areas of India. including metropolitan wells, sewer lines and a vision initially put forth by both Koshnevis Projects Timeline 600-meter-long river revetment wall. and Dini (who saw their technologies as fit In a high profile project for Milan Design to provide automated construction on other The two-year period between 2017 and 2018 Week, CyBe worked with a local architecture XtreeE proved its capabilities by constructing planets, as well as on Earth), COBOD and PERI saw more construction projects take form firm in Milan, CLS Architetti, to build (and telecom towers, while S-squared built a continue to undertake larger and larger on-site than all the previous 11 years combined. In furnish) an entire house right next to the city 500-square-foot house in 12 hours on Long construction projects, showing that the initial 2017, Europe really began to implement center. The project was completed in just Island (NY). ACCIONA finished a construction “one-floor” limit has been overcome, thanks construction 3D printing through several one week, in time for the week-long series 3D printing center in the UAE to run new in part to new cement mixtures developed projects, with actual buildings starting to rise. of events associated with the largest global projects in, and ETH’s D-Fab house was specifically for construction 3D printing by In European Russia, AMT built the first live-in furniture design show. completed and opened to the public. Italcementi. house (for AMT’s founder and his family), while Apis Cor obtained international recognition for As Dutch companies CyBe, Bruil and TAM building— and finishing—a house in just over 2019: Concrete progress 2020: We have a market expand to new territories (New Zealand) and one day. In Denmark, COBOD (3D Printhuset with new applications (an entire circular at the time) built an office-hotel structure Projects Timeline Projects Timeline viaduct and a Fibonacci-spiral-shaped house), known as The BOD. American companies Black Buffalo 3D, The period between 2019 and 2020 can be In 2020, with new construction 3D printing Mighty Buildings and Peri venture into ever Several other experimental, academic and understood as the culmination of this first projects now emerging almost every week, larger, more ambitious and more creative commercial projects continued to emerge phase of development for construction 3D we can safely say that “we have a market”. construction projects. in 2017. One of the most relevant was started printing. The next phase— expected to take Most commercial projects now involve in Zurich by ETH’s dbt (Digital Building place over the course of this decade—will large-format cartesian or robotic extrusion Even if we inevitably provided only a partial Technologies) department. The D-Fab house look to real mass market and massive-sized systems, however other innovative methods picture of the overall construction 3D printing combined all digital construction 3D printing operations. of implementing 3D printing into modular market, it is clear that the trend is accelerating technologies, including direct cement In 2019, several technologies matured enough construction continue to emerge. For example, exponentially, both in terms of project number extrusion and the use of voxeljet binder jetting to undertake some very large projects. the beautiful New Delft Blue Arch by Studio and size. We now have a market. Soon we’ll to produce complex construction formworks. ICON upgraded its Vulcan 3D printer and RAP, which uses 3D printed ceramic tiles, or have a global industry. ◆

AM Focus 2020 Construction AM / Analysis 15 Spotlight

A Massivit acceleration to the adoption of 3D

printing in construction A example of a large 3D printed mold for concrete and plaster casting for use in architecture, street furniture, restoration, created on a Massivit 1800 Pro system. Image: Massivit 3D

Large 3D printed tools add AM’s geometric

advantages to traditional materials and processes The introduction of 3D printing – in any form By providing cost effective 3D printed tools – into the construction industry is among to leverage the geometric benefits of AM, the most fascinating and, at the same time, without foregoing the use of traditional challenging endeavor. On the one hand, materials, Massivit 3D is enabling innovative the most advanced and technologically constructions and restorations. These complex, digital manufacturing processes; projects – from statues to capitols and on the other an industry that has notoriously decorations of historical Italian palaces been slow to introduce change. For these – would not have been cost-effective by reasons many see construction as the area either traditional construction methods or with the highest potential for 3D printing direct concrete 3D printing. innovation. And business. The shift is going to be gradual and any potential adopter In order to understand how this is possible will benefit from introducing 3D printing we need to take a step back and look technologies that can significantly enhance at Massivit 3D’s unique Gel Dispensing traditional construction practices. Massivit Printing (GDP) technology. The company’s 3D’s large-volume 3D printing technology large format Massivit 1800 3D printer for construction is doing just that. extrudes the Dimengel 100 and Dimengel

In collaboration with AM Focus 2020 Construction AM / Spotlight 17 Combination of reusable Geoplast formworks with large, custom casting joints 3D printed on a Massivit 1800 Pro by Janne Kyttanen. Image: Janne Kyttanen “Massivit 3D printing technology The result is an optimized structure for construction molds is ideal for that uses far less concrete. The ability to produce hollow joints and end parts allows for minimal use of printing materials as one offs, short runs, or complicated well as overall reduced use of concrete by creating more efficient structural elements. objects that would not be cost In addition, it eliminates the bottlenecks deriving from the lengthy multi-step process effective or feasible otherwise.” required for producing a silicon mold from a master pattern. Finally, unlike direct IDO DE-LA-VEGA, APPLICATIONS TEAM MANAGER, MASSIVIT 3D construction 3D printing technologies, it allows for the use of any traditional concrete material mixtures. Massivit 3D’s Dimengel 100 and Massivit 3D’s Dimengel. Other which was the first Italian business to is resilient to any type of chemical corrosion variations of concrete and plaster can also adopt a Massivit 1800 3D printer. from concrete or plaster, including a large be used. In particular, polymer concrete is After initially acquiring the solution to variety of polymeric concrete and polymeric a very strong material, suitable for building provide customers with interior design plasters. This enables the production of applications. It includes a balanced mix applications, the company recognized a robust, intricate structures without the need of Portland cement, , water, silica gap in the restoration market that could to use a release agent. fume, CSA (to speed up curing), glass fiber, be solved using rapid, large format 3D 90 proprietary photopolymeric acrylic ADMIX mixture (to improve mechanical printing. In a recent project the firm built gel materials. As the materials are cured Re-learning to build properties) and plasticizer. Metal five life-size capitals for the Grand Spada by UV light during extrusion and do not reinforcements can be added during the Palace in Ferrara. require cooling, the process is rapid and While it does provide a more accessible casting. The mold can finally be removed cost effective. Applications of Massivit 3D’s approach to construction 3D printing, the by using just a chisel, hammer and pliers, technology have already been broadly use of Massivit 3D technology for 3D printing or by heating the mold with a heating gun With a build volume of 145cm x 111cm x 180cm the Massivit adopted in the scenic entertainment formworks is a state-of-the-art technology to make it softer and easier to peel off. 1800 Pro system offers unparalleled performance for 3D printing large-volume construction parts and tools. ­­­­and growing 3D visual marketing that leverages advanced digital tools. Massivit Image: Massivit 3D sector. The benefits of this process in Smart V4.5 Pro software uses an algorithm Applications: past and future concrete construction are now becoming that enables the printing of hollow objects. increasingly evident in the production of The software also supports mold preparation Construction applications with Massivit concrete casting molds and potentially full by enabling the micro support to be printed 3D’s technology already expand beyond size formworks. on the external surface of a mold, thereby tools and casts. Some direct 3D printing allowing the inside of the mold to remain applications are also possible, either using Through a combination of the Massivit smooth enough for casting. As Ido De-La- the polymer material gel alone or by SMART V4.5 software’s advanced Vega, Applications Team Manager at Massivit finishing the polymer printed parts with capabilities to reduce material use, and 3D explains “the technology is ideal for one plaster and painting them in the same the low cost of the Dimengel materials, offs, short runs, or complicated objects color as the original counterparts to ensure the process is extremely sustainable, both that would not be cost effective or feasible an authentic look. economically and environmentally, while otherwise”. A wide variety of materials can also providing very significant design be poured into the 3D printed mold, but Some of the first direct applications of benefits in terms of geometry freedom for concrete and plaster are ideal as there is no Massivit 3D’s technology in construction columns, slabs and walls. chemical adhesion between these materials were carried out in Italy by Sismaitalia,

AM Focus 2020 Construction AM / Spotlight 19 RECENT EDITIONS

OCTOBER Metal AM

In this segment, we not only analyze the current state of metal additive manufacturing for industrial applications, but also look at where the technology, in all its iterations, is headed and what trends to watch out for.

Read now

Sismaitalia, the first Italian business to adopt a Massivit 1800 3D printer, used it to build five life-size capitals for the Grand Spada Palace in Ferrara. Image: Massivit 3D

Traditional restoration methods involve An even more direct application was prolonged turnaround times, mostly due to introduced by Q-Ads in Thailand. The the manual labor required. “This enables me company took Massivit 3D’s construction SEPTEMBER Dental AM to realize large projects in short timeframes capabilities into the future with a set of without compromising on the aesthetics,” 3D printed arches for the Ozone Hotel The dental segment has been a critical driver of AM adoption. Read now confirmed Alberto Apostoli, Architect at in Bangkok. Due to the translucent Today, dental labs across the world are using AM to improve Studio Alberto Apostoli.” With 3D printing nature of Massivit 3D’s DIMENGEL 100 patient care and to streamline production the five capitals were produced in two printing material, the arches could also be sizes, with the largest nearly one meter tall illuminated internally for stunning effect. in just a couple of days of print time. This turnaround speed was enabled partly by the In the future, different combinations of Massivit 1800’s two printing heads which all these methods will be increasingly allow separate models or parts to be printed integrated with direct construction 3D AUGUST AM Service Bureaus in parallel. Once filled, each capital was printing technologies for extremely large finished with plaster and painted the same building projects. Either way Massivit 3D AM service bureaus play an integral role in the AM industry. Read now color as the original counterparts to ensure will play a massive role in enabling more This eBook showcases how they are well positioned to an authentic look. construction 3D printing applications. ◆ encourage AM adoption across various industries. “A tu per tu” with Enrico Dini Enrico Dini’s journey in the construction AM space is marked by many ups and downs, but there is no question that the Italian inventor is a real pioneer of the technology. Image: D-Shape Face to face with the inventor of construction binder jetting Throughout history, many Italian geniuses For one, Enrico Dini also has an American never reaped the benefits of their inventions. counterpart, USC professor Berohk Koshnevis. Just think of Galileo, excommunicated by In this case, however, they are friends and the Roman Catholic Church for having share many accomplishments and mutual understood the motion of planets. Or more respect. They also share the fact that both recently Meucci who invented the telephone of their ideas were “borrowed” by other only to have Graham Bell obtain the patent entrepreneurs from around the world and and build an empire with it. Many great gave rise to what is now a strong trend for visionaries had to leave Italy—and continue construction 3D printing. to have to leave Italy—to find someone willing to finance their ventures, starting with How much of this business will go to those Columbus, who turned to the queen of Spain who invented the concept? Probably not in order to set sail on the voyage that would that much. I recently caught up with Enrico lead to the Americas. The story of Enrico Dini, at his construction facility in Tuscany, and I the man who invented the idea of 3D printing asked him to go through all the important concrete houses by binder jetting, is in many milestones that led him to where he is today: ways a modern version of these: an odyssey the founder of D-Shape and Dini Engineering for the future of construction, one that shares and also the man who invented construction some similarities with these great stories. 3D printing by binder jetting.

AM Focus 2020 Construction AM / Interview 23 The 3D printed Root Chair, created in 2009, was designed by KOL/MAC LLC Architecture + Design and printed by D-Shape. Image: D-Shape

and I decided I had to diversify. We worked actually the very first to publish anything on on several inventions, one on hydrogen automated cement construction processes, production for mobility. At the time, we were envisioning an intermediate process to glue also using a Zcorp (now 3D Systems) system sand layers together with a Portland cement for shoe modeling. I took a Zcorp system paste. Unlike the conventional approach to Piaggio to offer it as a of casting concrete into a formwork, 3DCP device, and, while the presentation was a would combine digital technology and new disaster, that’s where we first had the idea for insights from materials technology to allow scaling up this technology to 3D print a full- freeform construction without the use of size house.” expensive formwork.

Dini experimented with sand and water “At the time I was totally unaware that (incidentally creating the very first 3D printed there was a professor in the US, a certain sand castle) and, a few years later, met up Behrock Koshnevis, who was also working with constructor Roberto Nannini. With on this concept,” Enrico tells me. He and Nannini and Moreno Chiarugi, Dini deposited his business partners were looking for the very first construction 3D printing funds and were able to meet with Italian patent (Method and Device for Building industrial moguls such as the president of Automatically Conglomerate Structures) in Smeg, who arranged a meeting with Carlo 2005. The challenge then became to find Pesenti, President of Italcementi, one of the proper financing. The patent was based on largest construction groups in the world. sand and epoxy resins, rather than cement. Unfortunately, that also led nowhere. Dini This approach was chosen to avoid any risk was welcomed by an 80-year-old engineer Enrico Dini’s great invention is not just the my own time and money into this project of infringement on other patents concerning who did not understand the idea’s potential. idea of using 3D printing with building and, while we have certainly reached some cement-based automation processes, such as The project was then placed on hold and materials. His technology is not just based significant milestones and implemented our one held by Joseph Pegna, who in 1997 was Enrico separated from his two partners who, on 2D plotting—or multiaxial 2D plotting— technology in several interesting projects in the meantime, had begun working on like most commercially available digital around the world, I can’t say that it has been their own construction 3D printing concept construction technologies today. From the easy nor that those with whom we’ve shared using a gantry system on a CNC machine. Dini specializes in a construction AM process based on very start, Dini implemented a very large- this journey have always been fair.” binder jetting, capable of printing complex geometries. format binder jetting process, which, in his Image: D-Shape Going global and back mind, could truly deliver the promise of How did construction 3D printing begin? virtually unlimited geometric freedom in Enrico then moved to the UK, where he construction. Dini is a celebrity in 3D printing “Let’s take a step back to 2004. Nokia phones founded Monolite UK Ltd., the first firm today but also a very down to earth person, and no iPhones,” he says. “The construction entirely dedicated to building houses using very friendly and very willing—perhaps too world was as far from robotic technologies additive manufacturing technologies. willing—to open his heart and mind. as could be. As an engineer who came from While in the UK, Enrico learned about the world of robotics and shoe industry Koshnevis, who was in touch with Rupert “I do worry that every time I share my automation in Italy, I quickly realized that, Soar, who, in turn, was one of the first to accomplishment some just try to take under the unified euro regime, I could not 3D print—or 3D plot—a large sculpture advantage of it,” he admits as we begin talking compete with stronger German and French in cement. Galvanized by the presence of about his journey. “I invested so much of companies. I was programming Kuka robots other entrepreneurs, and confident in the

AM Focus 2020 Construction AM / Interview 25 “All the companies that have superior capabilities of his binder jetting When Dini showed this sculpture to a based approach, Dini made a big decision: in financial consultant, he took him to meet sprouted around the world since order to get the money to 3D print houses, he with another large cement construction sold his. group that agreed to finance the project then are—in one way or another— with €50 million, of which €17 million was He used this money to build the very first for Dini’s company. Dini took out a loan connected to our work.” factory in Italy and his first large-format 3D waiting for the money to come through. printer. Here, he 3D printed the now famous However, the money never did. The bank and radiolaria sculpture, designed by Andrea investors pulled out from the project citing Morgante. In order to avoid any possible the economic crisis of 2008 as motivation. new manager refused and set his mind on all in some way inspired by our work. We also patent clash with Pegna, Koshnevis and Dini returned to Italy and founded a new producing and selling cement products collaborated with IaaC in Catalunya, with voxeljet, Dini used magnesium-oxide for company, Dinitech, and sold his machine using Dini’s technology. Sofoklis Giannkopoulos, and even formalized powder and magnesium chloride for binder. to the new company for $400,000 and a our relationship to a certain degree. On that “When I learned that WinSun in China totally 40% stake in the company. However, the Unfortunately, most of these projects also fell wave, we worked with Acciona in Madrid and disregarded any patent from Koshnevis or company ran through one million euro in just through. All but one: the very first 3D printed built a 3D printer for them to create the very anyone else, I realized I may have been a bit over a year. Even though there was interest house, built for Milan’s Triennale Museum. first 3D printed cement bridge. It was a tribute overly cautious,” Dini admits. from other industry groups, the company’s The technology demonstrator project, called to my father, who was a bridge builder.” “Una casa tutta d’un pezzo” (A house in one piece), should be considered the first Dini’s work, however, is not just about An overhead view of the full-size D-Shape binder complete 3D printed house. building bridges in the sky: many 3D printed jetting construction 3D printer invented by Dini “This house did not get any visibility,” Dini construction projects for defense, in the arts Image: D-Shape remembers. “However, what got a lot of and in other construction segments (coral visibility was a section of free form wall, barriers, public benches) were successful both which arrived all the way to China and for their innovative approach and from the led WinSun’s founder—a kid who did an economic side of things. Dini has also sold a internship with Koshnevis in California—to few machines around the world so the future produce, four years later, the 3D printed does look bright. office for the ruler of Dubai.” Binder jetting—a technology that seemed Since then, dozens of companies have to be born old—is now looking more and emerged but only a few of them proved more like a key 3D printing technology for profitable for Dini and his company. “All the future, as the almost infinite geometric the companies that have sprouted around possibilities it offers become more relevant the world since then are—in one way or than its limitations and complexity. Still today, another—connected to our work,” Dini Dini’s technology is the only construction says. “In the Netherlands, where I gave technology—together with voxeljet’s to a one of my first conferences, they followed certain extent—based on a binder jetting up with a large-format project based on approach. Who will reap the benefits of this thermoplastics. Now COBOD, founded by potential is still not clear. Dini’s work may not my friend Erik Lund Nielsen, is also doing get the economic recognition it deserves for some important work, as is CyBe in the many years, but one thing is for sure: more Netherlands and XtreeE in France. They were houses will be 3D printed. ◆

AM Focus 2020 Construction AM / Interview 27 Printing a three- story apartment

building with COBOD German construction firm PERI is embarking on its most ambitious AM project to date: building a three-story apartment building using the COBOD 3D printer.. technology Image: PERI Group | COBOD

Since Danish construction company To span 380 meters square, the 3D Brick by brick? More like layer by layer. COBOD spun out of 3D Printhuset in 2018, printed apartment block is being built in it has made steady advances in pushing Wallenhausen, Germany in cooperation with construction AM towards the mainstream. German concrete specialist PERI, which invested in COBOD back in 2018. COBOD’s In the past year alone, its gantry-based 3D BOD2 3D printer has been deployed to print printing technology has been used for a the walls of the house on-site. The printing handful of large-scale projects, including is well underway and is expected to be building over three demo houses in only completed as soon as mid-December. When a four-day span (at the International the entire construction is complete—by April Bautec construction exhibition), and 3D 2021—the commercial apartment building will printing a two-story residential building consist of five units that will be rented out. in Beckum, Germany—the first of its kind in the European nation. Today, COBOD’s “We are incredibly pleased, that we are technology is pushing its own boundaries beginning to see the fruits of the many with the construction of a three-floor 3D construction printers we have sold,” apartment building. commented Henrik Lund-Nielsen, Founder

AM Focus 2020 Construction AM / Latest 29 Newsletter “The commercial nature of the building proves the competitiveness of the 3D construction printing technology.”

and General Manager of COBOD. “The actual demonstrating that this new technology can building projects have been delayed by also be used to print large scale dwellings the coronavirus, but now they start to be units. In terms of 3D construction printing, revealed. This new German project is really we are opening up additional areas of a great milestone as the commercial nature application on an entirely new level.” of the building proves the competitiveness of the 3D construction printing technology The apartment building’s walls are being for three floors buildings and apartment printed using a BOD2 system with a 12.5 x buildings. This, again, opens entirely new 20 x 7.5 meter configuration. The 3D printer Additive Insights markets for our printers.” is capable of reaching speeds of up to 100 cm/second, the equivalent of printing PERI, which will be leading the printing or casting 10 tons of concrete per hour. That Matter of the three-flour building, sees a bright The walls themselves will be made from future for AM in the construction sector. a special 3D printable concrete material Since investing in COBOD, the company developed by Italcementi, a subsidiary of has been involved in many projects, not HeidelbergCement. Carefully curated additive manufacturing insights and only leveraging the BOD2 to build various structures but also selling the printer to When the project is complete, the three- the week’s top stories sent directly to your inbox clients, including Röser GmbH. In short, floor block will be owned by Michael Rupp PERI is playing an important role in Bauunternehmung GmbH, a local, family- COBOD’s journey and is actively promoting owned construction firm. Sebastian Rupp, Breaking industry news Exclusive interviews construction AM. future managing director at Michael Rupp Market analyses & forecasts Case studies & applications Bauunternehmung, said of the firm’s “We are very confident that 3D construction involvement: “We believe that this new printing will become increasingly important technology has enormous potential for in certain market segments over the coming the future, and we want to help shape that years and has considerable potential,” said future. Despite the traditional nature of Thomas Imbacher, Innovation and Marketing our craft, we are also innovative and do not 3dpbm.com/newsletter Director at PERI GmbH. “By printing the shy away from new challenges—quite the first apartment building on-site, we are opposite in fact.” ◆

Take a look A shared vision for sustainable housing comes to life with Lofts to Go is nearing market readiness for its flagship coodo living solution, but it is also developing 3D printed units in collaboration with Black Buffalo 3D. 3D printing Image: LTG Lofts to Go

A remote community, where people can another plan in the works, which will take its Exclusive interview with Lofts to Go’s Jens Rosenthal spend time reconnecting with nature while vision for sustainable living and tourism to enjoying the comforts of a sustainable the next level. This particular project, which and Black Buffalo 3D’s Peter Cooperman. dwelling. Connecting with others while still we’ll dive into in the following interview, is having space for themselves. Sounds like a supported by construction 3D printing and dream doesn’t it? For Lofts to Go (LTG), this New York-based Black Buffalo 3D. vision is more than a dream; every day it is one step closer to being a reality. Meet Black Buffalo 3D

Founded in 2012, LTG has set out to develop Black Buffalo 3D is a promising player in eco-friendly tiny houses using innovative the additive construction world. But its role design and production techniques. Today, isn’t quite as straightforward as “printer the company is nearing market readiness for developer”. Black Buffalo 3D is a U.S. affiliate its flagship coodo modular living solution, of Hyundai BS&C, a large South Korea-based which consists of flatpack homes that can be company specializing in IT and construction. assembled on site. In fact, LTG is preparing to open its first coodo resort—with over 100 Peter Cooperman, Black Buffalo 3D’s Head units—in Germany next year. Despite this of Marketing, explains the parent company’s already ambitious undertaking, LTG has role in the construction area: “Since 2008,

AM Focus 2020 Construction AM / Interview 33 “3D printing will enable us to they’ve been involved in the construction A partnership is born and technology industries and today they have a lot of companies that are focused It seems fated, therefore, that Lofts to Go and bring our tiny houses to various on different verticals, from small structures Black Buffalo 3D should find each other and to high-rise buildings and everything form a partnership. Jens Rosenthal, LTG’s regions in the world and to speed up in between. A few years ago, Hyundai Director of Resorts and Brands, explains BS&C’s founder pursued and acquired a how the connection was born: “We were construction time.” construction 3D printing company—HISYS— searching for a 3D printing partner, and and they’ve since been working on fine our CEO traveled the world to meet with tuning and improving their technology. several firms. We were also talking with Black Buffalo 3D was established as a U.S. the Fraunhofer Institute here in Germany companies are currently working together icon. But setting up coodo resorts means affiliate and sister company of the R&D arm because they work with 3D printing. to fine tune the 3D printing technology and more than simply placing 500 of the in South Korea.” Eventually, we were approached by Black materials as well as the tredee’s design. same unit somewhere. We wanted some Buffalo 3D.” diversity in design. Travelers have different To specify, Black Buffalo 3D is the global Cooperman adds: “We reached out because “Everything is moving towards the highest requirements in terms of space and layout. sales distribution arm for Hyundai BS&C’s we feel that in all partnerships, it’s really quality and we are really thrilled to be working We also needed to think about amenities. I construction 3D printing technology, but important for the teams to mesh well and with Black Buffalo 3D,” said Rosenthal. “We very much appreciate 3D printing because it also has its own engineering team and for there to be cohesion between both are now focusing on delivering the perfect it allows us to develop different models and factories. According to Cooperman, the businesses’ theories and missions. We product. It’s about sustainability, but it is also can be used to create interesting features company’s overarching mission is to provide really liked Lofts to Go and I think we have about new ways we can build together to such as restaurants and washrooms, etc. This scalable 3D construction printers and similar goals. One of our big pushes is achieve the best quality and most efficiency. is very important because we want coodo cement-based inks through partnerships in sustainability.” 3D printing will enable us to bring our tiny resorts to offer unique experiences without the construction, development and tourism houses to various regions in the world and sacrifice.” sectors. “The goal is to scale our technology Sustainability is one of the key connection will allow us to speed up construction time. with partners that excel in design and points between Lofts to Go and Black Buffalo At the moment, our conventional production 3D printing also has the potential to reduce tourism, like Lofts to Go, so we can bring 3D. Both companies see a future in which needs three to six months to set up a coodo construction costs for the coodo units. This construction AM to the world,” he says. housing and tourism are more ecological. resort, with 3D printing it could be as little as is due to a number of factors, including the For the former, this is achieved through 30 days.” high degree of automation associated with intelligent design and smaller footprints. For 3D printing vs traditional construction, as 3D printed coodo units could be placed anywhere, giving Black Buffalo 3D, sustainability is achieved In terms of structure, the treedee model has well as its on-site nature, which reduces the people access to live in remote, natural settings. on the construction side through on-site a modified design for 3D printing. It is more need for transporting construction materials. Image: LTG Lofts to Go production, which leads to fewer transport square than LTG’s signature coodo style, This benefit, paired with the sustainability emissions, as well as through the use of but it bears many of the same hallmarks, factor, is making 3D printing an important recyclable materials. The companies are including broad open windows, designed part of LTG’s future plans. joining these two visions in LTG’s new tredee for optimal immersion in nature. Presently, solution. the companies are working to automate the The tredee timeline construction process as much as possible so 3D printing tredee that it is fully scalable. Down the line, the aim Like most businesses, LTG and Black Buffalo is to ultimately 3D print the original coodo 3D were faced with supply chain challenges LTG’s tredee offering, powered by Black design and more. due to COVID-19. Despite these setbacks, the Buffalo 3D’s construction AM system, was “It’s important for us to make different companies are back on track to move ahead first unveiled in September 2020. Both models,” adds Rosenthal. “The coodo is our with tredee construction. One upcoming

AM Focus 2020 Construction AM / Interview 35 Black Buffalo 3D’s construction 3D printer is a large-format, gantry-based system, capable of printing structures on-site. UPCOMING EDITIONS Image: LTG Lofts to Go

DECEMBER AM 2021

With 2020 drawing to a close, we will take the opportunity to look ahead to 2021 in our final eBook of the year. In it we will forecast and analyze major trends in the industry that will shape additive manufacturing as it evolves in this decade.

Analysis Interviews Case Studies Mapping

milestone will be the launch of a test print in we also have a leased warehouse set up in the U.S. in Q1 2021 (other ongoing tests are New Jersey,” Cooperman explained. “We’re being carried out in South Korea). If all goes also working to acquire land officially, where well there, LTG plans to have the product we’ll actually print a permanent warehouse JAN Automotive JUL Maritime market ready as soon as Q2. towards the end of next year.” Black Buffalo FEB Medical AUG Post-Processing 3D’s printer, which will take on this project, “There are reasons we haven’t yet entered can print structures measuring up to 1,500 MAR Consumer SEP Service Bureaus 2021 CALENDAR the market with our coodo resorts,” square feet and up to four stories in height. APR Composites OCT Metal Rosenthal says. “In the past years, we have HAS LAUNCHED MAY Sustainability NOV really focused on optimizing the production Ultimately, LTG plans to sell coodo units JUN Aerospace DEC AM 2022 methods we want to work with. We worked in the resorts. The resorts will be operated on patents, quality improvements and so by LTG and partners in cooperation with on. What we are doing now is really laying members of the hospitality industry. As is out our big approach and we are doing that natural with these types of initiatives, there together with Black Buffalo 3D. Overall we are lots of ways to go about it. As Rosenthal want to introduce a new form of tourism, says, people can either buy coodos to live in Enquire about sponsorship opportunities where we can focus a little bit more on or they can rent them as holiday homes. Get in touch ourselves and be a bit more distanced from All that to say, if you’re looking to escape to Have an interesting story to share and want to reach each other. From our standpoint, we are a 3D printed holiday home, it won’t be long a broad network of professionals? Let’s talk. working with the team in South Korea but before it’s a possibility! ◆

AM Focus 2020 Construction AM / Interview 37 Just CyBe, the 3D printing company rethinking construction In 2018, CyBe’s robotic 3D printing technology was used to live-print a house at Milan Design Week. Image: CyBe

Discussing the state of construction AM with The construction 3D printing sector is being bench project is being led by local technology CyBe Founder and CEO Berry Hendriks pioneered by a relatively small number of company QOROX, which imported CyBe’s companies, each of which is presenting its construction 3D printer from Europe. own technology and vision for disrupting the global construction industry. Amongst them is To learn more about its technology, operations CyBe, a Netherlands-based company that has and philosophy, we spoke to CyBe Construction taken an encompassing and holistic approach Founder and CEO Berry Hendriks. He shared to construction AM. with us the foundation of his company, as well as how it continues to build up its construction The company has piqued our interest many AM offering. times over the years: first when it 3D printed an expansive drone laboratory in Dubai, and A construction legacy then again in 2018 when it supported the live-printing of a house at Milan Design Week. Hendriks has been a part of the Dutch Most recently, the company’s technology construction sector for longer than most. has been used in New Zealand’s first His family started and still runs a housing demonstration of robotic 3D printing for a construction firm in the Netherlands that was commercial concrete object: a park bench. The originally founded in 1922.

AM Focus 2020 Construction AM / Interview 39 “My father has taken me to construction sites The moment that really put Hendriks on In addition to working on construction 3D CyBe’s dynamic is clearly demonstrated when since I was little, and I even started to work the path to 3D printing, however, was when printing projects, CyBe also made progress looking at a current project it is working on for my family’s company during the school he watched Behrokh Khoshnevis’ Tedx with commercializing and starting to sell its in India. There, it is working closely with a holidays when I was about 11, in a factory Talk in 2012 about his Contour Crafting machines. In 2018, it delivered its first printer partner to build a G+7 apartment complex making window-frames, roofs and precast technology. “I know that it was a theoretical to a precast factory in Japan. Last year, it (eight stories). The India-based team concrete,” he tells us. “Then during my studies, presentation, but it didn’t seem that difficult,” sold many more and delivered two. Today, purchased the 3D printer, but they also hired I was able to do internships, which gave he remembers. “I analyzed it and thought: the company has machines in operation CyBe’s team in the Netherlands to design me a lot of real experience by a young age. you need material, hardware and software, as around the world—in New Zealand, Australia, and engineer the apartment complex. From Eventually, I did my master’s at the University well as a 3D model, but you could make a real Morocco, Qatar and Paraguay. “Our sales its end, the CyBe team is planning the entire of Eindhoven, and then went on to work at my product.” pipeline goes through to 2021,” Hendriks infrastructure, including developing the father’s company as a project manager and explains. “From a business perspective, we building mixture so that it integrates local project developer.” From there, Hendriks quit his father’s are covered until the beginning of 2022 with materials from India. company in 2013 and founded his own, CyBe production.” “I think that’s pretty unique,” he states. “What Hendriks’ knowledge of and experience in Construction. The company’s mission from we see with a lot of companies is that they the construction industry gave him a unique the beginning was to 3D print concrete wall The business model focus on only selling the printer or only design perspective and the realization that he wanted elements for houses with the aim of making engineering or printing themselves. I believe to play a part in changing the industry and construction faster, cheaper and more Hendriks emphasizes that CyBe is not only that since we are doing everything and those making it more efficient. In 2010, for instance, sustainable. “Back in 2013/2014, we developed focused on selling printers, it is also invested four units are also working together, we he led a team of architects and engineers in a prototype based on a robotics system. in supporting the design and engineering can improve the technology. If we can do it the design of 12 houses but radically changed Then in 2015, we entered into an accelerator process for its customers. In fact, the company ourselves, then we are in a better position to how the process was organized. “Normally program and really started to focus on the is subdivided into several departments, which provide the technology and support to our it takes about five months to really design business case,” he says. “We also understood give some indication of how it operates. customers. We are always looking to make and engineer houses,” he explains. “But since that we wouldn’t be able to change the a business case: we must build faster and I changed the way we were organized, we industry if we were just printing ourselves, we “We have a design and engineering cheaper compared to traditional construction.” achieved it within just two weeks.” needed to partner with other construction department for housing and other projects, companies globally so that we could help which is made up of architects, structural Hendriks elaborates on this idea further, them to solve their problems.” engineers and urban planners. They provide explaining that promoting the adoption of the 3D files to the 3D printing team,” he concrete AM is not just about demonstrating CyBe’s robotic construction 3D printing technology First jobs explains. “Then we also have in the COO the technology. He believes it is more uses an ABB robot as its basis, to facilitate system process-flow the 3D Concrete printing important to solve the business side. “We can maintenance around the globe. Image: CyBe Things moved rather quickly for CyBe in team which is focused on using our own sell somebody a printer, but it’s important its early years. The accelerator enabled the technology. On the product side, we have that eventually, the customer is going to earn company to establish its business and helped the CPO department, which consists of money with it. If they spend 200,000 euros on it secure its first collaborations. In 2015, for a team of software engineers, robotic a machine, we can indicate that within two or example, CyBe 3D printed wall elements for engineers, mechanical engineers and gaming three years, there is an ROI.” Heijmans for infrastructural projects. Then, software engineers. This is the team that in 2016, the company was granted a tender develops the printing technology, including The ABBs of construction 3D printing for the construction of a laboratory in Dubai. hardware and our two software programs, “Based on that project, we acquired another ARTYSAN and CHYSEL. And then we’ve got Turning towards the company’s technological project in Milan, and then another in Saudi the manufacturing department, which is offering, Hendriks sheds light on how CyBe’s Arabia, and it has been growing ever since,” manufacturing and selling the machines after concrete 3D printing technology works. Hendriks says. R&D is completed.” As with most AM processes, the technology

AM Focus 2020 Construction AM / Interview 41 is founded on three key things: hardware, euros per ton, but we also have a less fast- materials and software. CyBe’s system is setting mortar that costs about 200 euros per interesting in that it is based on existing ton.” hardware and software: ABB robots and Rhinoceros software. The combination of CyBe’ protected concrete mixture and the ABB robotic base has “Our system is based on an ABB robot enabled CyBe to achieve rapid deposition partially due to the fact that ABB has good rates. “Since we have a really fast setting global coverage,” he says. “If we are looking concrete, we can print at a speed of about at selling and providing maintenance to our 600 mm per second. If you printed at that customers around the world, we want to have speed with a gantry system, the dynamic partners in every country that can provide forces on such a printer would be too big the necessary degree of service and support.” and the entire installation would crack. The CyBe robot itself is available in three ABB’s robotic system is designed to make configurations: the CyBe R, a fixed 3D printer; such quick movements.” The robotic system the CyBe RC, which is fixed to a mobile is designed to build wall elements onsite, crawler; and the CyBe RT, which is a robot on which can then be assembled using a crane. a track. These robotic systems are controlled Hendriks illustrates this idea, saying: “For the by two Rhino-supported software tools and G+7 apartment complex, we can print four CHYSEL, CyBe’s special slicing software. “We elements on the first day. Our concrete is load use Rhino because most architects nowadays bearing and can be hoisted into place using a CyBe’s 3D printing technology has the ability to print at are taught to use parametric design in crane within one hour of printing. As a result, rapid deposition rates of up to 600 mm per second. Image: CyBe Rhino. We like to make use of platforms that as elements are being printed, earlier ones already exist, like Rhino and ABB. We’re not can be hoisted, and so on. We are capable reinventing the wheel here, we want to find of generating a really fast construction the right combination of existing systems to sequence: such an apartment complex can make our optimal 3D printer.” be built within just two months.” different products being built, like factories, can help to automate the construction process. houses, offices, roads, tunnels, bridges, There is also the issue of how we design houses: In terms of the 3D printable concrete Will construction 3D printing reach the windmills, etc. Each of those products has its they should be energy neutral, and 3D printing material, details about CyBe’s special mainstream? own optimal processes,” Hendriks says. “In can help there.” MORTAR are still very much under wraps. addition to that, each country has different Hendriks explains that he spent a long With a fairly new technology like construction ways of building and regulations. Due to While Hendriks recognizes that there are time finding the right partner to develop a 3D printing, it is always interesting to think the fragmented nature of the industry, I do many potential applications for construction printable, fast-setting concrete with. “Back of how big of an impact it will have on its think that the number of applications for 3D printing, he’s most interested in housing, in 2013, I came across a family-run company larger industry, and whether it will become construction 3D printing will grow, but not the segment that his family’s company has that had this really fast-setting concrete, mainstream. In this case, it doesn’t seem everyone will use it. worked in for nearly a century. “I think if we so the CyBe MORTAR is a co-development likely that every construction project in the want to change the way we design, engineer with them. The material is 30% our special future will be 3D printed, however, that “If you look at the global issues we are facing, and build houses, we should not only focus on compound and 70% sand, and this can be doesn’t mean that most construction jobs there is a housing shortage because of the printing element,” he concludes. “We have sourced locally. We can also play with our won’t involve 3D printing in some way. population growth. There will also be a labor a holistic view and as a result, we’ve created a compound to achieve different properties “The construction sector is approximately a shortage in construction because the work is platform that is accessible to all our customers and costs. Our regular material is about 360 $12 trillion industry and there are so many hard and in a harsh environment. 3D printing and facilitates the entire printing process.” ◆

AM Focus 2020 Construction AM / Interview 43 Image Credits

Cover © PERI Group | COBOD

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Page 20. © Massive 3D © 2020 3D Printing Business Media Ltd All Rights Reserved. Page 23. © ExOne This document and its contents are the property of 3D Printing Page 23. © D-Shape Business Media Ltd (hereinafter referred to as “3dpbm”).

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