Hybrid Thermoplastic-Composite Building Components

Abstract

The development of additive manufacturing (AM) technology has unlocked new geometric and material potentials for architecture and construction. While large-scale implementation of AM continues to be a popular research topic, the majority of projects are restricted to traditional planar layer-based printing methods. Furthermore, many modern large-scale 3D printing machines rely on heavy cementitious material, which further limits the benefits which can be gained from additive processes. These traditional printing methods restrict construction to mainly vertical walls with roof structures and overhangs posing major challenges. Robotic fabrication and materials research present opportunities for effective and efficient applications of AM in architecture. The following research takes place over several phases and explores fabrication strategies which combine AM and fiber composites to produce lightweight building components. (1) The first phase tests the material capabilities of a reinforced AM system, including the production and testing of several hybrid material systems. An emphasis is placed on sustainable alternatives to traditional concretes and polymers. (2) The second phase develops, tests, and refines hybrid material fabrication processes, which include printing on complex formwork and composite substrates. (3) Phase three includes material investigations, manufacturing processes, and geometric iterations to determine the compatibility of various recycled thermoplastics and textile/film membranes. Custom and adaptable robotic AM techniques take advantage of 9 axis fabrication to 3D print material efficient, non-planar, and geometrically differentiated components. (4) The final phase further explores and develops the geometric potential of the developed fabrication processes and material systems. Numerous building components are 3D printed and tested for structural capabilities. These components are assembled into a full-scale demonstrator which explores various architectural potentials of the system including cantilevering structures, roof systems, multi-material assemblies, joint logics, enclosure systems, and scalar limitations. This project showcases the potential for lightweight composite reinforced additive manufacturing processes for large-scale architectural applications.