UC Irvine UC Irvine Electronic Theses and Dissertations Title State-of-the-Art Review on 3D Printing Technology Applications in Construction Permalink https://escholarship.org/uc/item/4m27c4xs Author Truong, Andrew Publication Date 2019 Peer reviewed|Thesis/dissertation eScholarship.org Powered by the California Digital Library University of California UNIVERSITY OF CALIFORNIA, IRVINE State-of-the-Art Review on 3D Printing Technology Applications in Construction THESIS submitted in partial satisfaction of the requirements for the degree of MASTER OF SCIENCE By Andrew Truong Thesis Committee: Professor: Ayman Mosallam, Chair Assistant Professor: Mohammad Javad A. Qomi Assistant Professor: Joel Lanning 2019 © 2019 Andrew Wesley Truong DEDICATION To my parents and friends in recognition of their kindness ii TABLE OF CONTENT LIST OF FIGURES ..................................................................................................................... v LIST OF TABLES .................................................................................................................... vii ACKNOWLEDGEMENTS ..................................................................................................... viii ABSTRACT OF THE THESIS ................................................................................................. ix CHAPTER 1 .................................................................................................................................. 1 INTRODUCTION ....................................................................................................................... 1 1.1 GENERAL ............................................................................................................................ 1 1.2 THESIS ORGANIZATION .................................................................................................. 1 1.3 HISTORY OF THREE-DIMENSIONAL (3D) PRINTING TECHNOLOGY .................... 2 1.4 HISTORY OF CONCRETE 3D PRINTING ........................................................................ 8 1.5 SUMMARY ........................................................................................................................ 12 CHAPTER 2 ................................................................................................................................ 14 THREE-DIMENSIONAL (3D) PRINTING TECHNOLOGY ................................................ 14 2.1 GENERAL .......................................................................................................................... 14 2.2 SUMMARY OF 3D PRINTING PROCESS ...................................................................... 14 2.3 MAIN COMPONENTS OF A TYPICAL 3D PRINTING MACHINE ............................. 15 2.4 MATERIALS COMMONLY USED FOR 3D PRINTING ............................................... 19 2.5 STRENGTH PROPERTIES OF CONCRETE 3D PRINTING .......................................... 23 2.6 MODIFICATIONS OF 3D PRINTING MACHINE FOR CONSTRUCTION APPLICATIONS ...................................................................................................................... 28 CHAPTER 3 ................................................................................................................................ 30 APPLICATION OF 3D PRINTING TECHNOLOGY IN CONSTRUCTION........................ 30 ® 3.1 CyBe CONSTRUCTION .................................................................................................. 30 ® 3.2 ICON 3D PRINTED HOUSE ........................................................................................... 30 ® 3.3 WinSun BUILDING TECHNIQUE ................................................................................. 32 ® 3.4 TOTAL KUSTOM ............................................................................................................ 33 ® 3.5 APIS COR ......................................................................................................................... 35 ™ 3.6 WASP ............................................................................................................................... 36 3.7 TU EINDHOVEN UNIVERSITY ...................................................................................... 37 3.8 University of Nantes............................................................................................................ 38 CHAPTER 4 ................................................................................................................................ 39 iii POTENTIAL USE OF 3D PRINTING ON PLANET MARS ................................................. 39 4.1 GENERAL .......................................................................................................................... 39 4.2 WHY 3D PRINT ON MARS .............................................................................................. 39 4.3 3D PRINTED HABITAT.................................................................................................... 40 4.4 BASALT REINFORCED POLYMER 3D PRINTING...................................................... 45 4.5 CONCRETE REGOLITH MIX DESIGN .......................................................................... 46 4.6 REGOLITH DERIVED FEEDSTOCK FOR 3D PRINTED CONSTRUCTION .............. 49 4.7 HARVESTING WITH ELECTROMAGNETIC SOIL SIEVE DISTRIBUTION ............ 54 4.8 3D PRINTING REGOLITH MATERIAL PROPERTIES ................................................. 56 4.9 CONCLUSIONS ................................................................................................................. 57 CHAPTER 5 ................................................................................................................................ 59 DESIGN AND MODIFICATION OF 3D PRINTING MACHINE ......................................... 59 FOR PRINTING CONCRETE ................................................................................................. 59 5.1 GENERAL .......................................................................................................................... 59 5.2 MODIFYING THE 3D PRINTER ...................................................................................... 60 5.3 MATERIALS AND EQUIPMENT .................................................................................... 61 5.4 CONFIGURING IN ARDUINO ......................................................................................... 62 5.5 CONFIGURING FIRMWARE ........................................................................................... 63 5.6 UPLOADING FIRMWARE TO 3D PRINTER ................................................................. 65 5.7 CREATING A 3D MODEL ................................................................................................ 65 ® ® ® 5.8 SLICING THE 3D MODEL (Cura , Slic3r , Makerware , etc.) ...................................... 66 5.9 PRINTING 3D OBJECT ..................................................................................................... 68 5.10 TROUBLESHOOTING .................................................................................................... 69 5.11 CONFIGURATION LOG ................................................................................................. 70 CHAPTER 6 ................................................................................................................................ 76 CONCLUSIONS & RECOMMENDATIONS FOR FUTURE RESEARCH .......................... 76 6.1 GENERAL .......................................................................................................................... 76 6.2 CONCLUSIONS ................................................................................................................. 76 6.3 RECOMMENDATIONS FOR FUTURE RESEARCH ..................................................... 77 REFERENCES ............................................................................................................................ 78 iv LIST OF FIGURES Figure 1.1: The SLA-1 [3] ............................................................................................................. 3 Figure 1.2: SLS Process [Source: https://formlabs.com/blog/what-is-selective-laser-sintering/] . 4 Figure 1.3: Close ups of the first plastic powder Deckard used in his SLS project before (top) and after (bottom) sintering process. [76] ....................................................................................... 4 Figure 1.4: Examples of 3D Printing Medical Applications [8] ................................................... 5 Figure 1.5: The first version of RepRap design (Mendel) [Source: https://reprap.org/wiki/Build_A_RepRap]...................................................................................... 6 Figure 1.6: First Fuel-Efficient 3D Printed Car is Back on the Map [9] ....................................... 7 Figure 1.7: 3D Food Printing [10] ................................................................................................. 8 Figure 1.8: A concrete form of desired span and height fabricated by the CC machine [12] ....... 9 Figure 1.9: The printed Wonder Bench [14] ................................................................................ 10 Figure 1.10: XtreeE™ - 3D Printed wall with integrated window frame [16] ............................. 11 Figure 1.11: ICON Build 3D Printed House [18] ........................................................................ 12 Figure 2.1: 3D concrete printer in operation.