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Contour Crafting Printing 3D printing
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Viterbi School of Engineering .
USC
Mega-Scale FabricationMega-Scale Fabrication byby Contour CraftingContour Crafting
Behrokh KhoshnevisUniversity of Southern California
Viterbi School of Engineering .
USC
Fabrication Processes
• Subtractive (milling, turning, chiseling, sawing,..)
• Formative (pressing, forging, bending,..)
• Additive
– Casting (requiring mold)
– Traditional Layered Fabrication in manual construction
– Modern Layered Fabrication (SFF or RP) Technologies
Viterbi School of Engineering .
USC
Limitations of current SFF methods
• Slow speed• Not scalable• Limited choice of materials• Impossible to embed other objects
Viterbi School of Engineering .
USC
What is Contour Crafting?
Material feed barrel
Nozzle
Side trowel
Side trowel control mechanism
Top trowel
CC is a layered fabrication method which combines ancient surface forming concepts with modern robotics technology
Viterbi School of Engineering .
USC
Movable Side Trowel
Cylinder
Connector
Bevel gear
Nozzle
Side trowel
mechanism of movable side trowel
Viterbi School of Engineering .
USC
Maslow’s Hierarchy of Needs
Self Actualization Needs (full potential)
Ego Needs (self respect, personal worth, autonomy)
Social Needs (love, friendship, comradeship)
Security Needs (protection from danger)
Physiological Needs (food, shelter)
Viterbi School of Engineering .
USC
Why automate construction?
• Labor efficiency is alarmingly low
• Skilled workforce is vanishing
• Work quality is low
• Control of the construction site is insufficient and difficult
• Accident rate at construction sites is high (> 400,000 / year in US)
• Waste and trims are high (3 To 7 tons per average home; 40% of all materials used
worldwide are for construction)
• Low income housing and emergency shelters are critical
• Construction is the largest sector of almost all economies
• All other products are fabricated automatically – construction is still
largely a manual task
Viterbi School of Engineering .
USC
Construction productivity decline
Labor productivity comparison for non-farm industries and construction industry developed by Paul Teicholz
Construction Productivity index
Non-farm productivity index
Viterbi School of Engineering .
USC
Edison’s concrete houses
$175,000 for molds
More than 2000 pieces
500,000 pounds
Viterbi School of Engineering .
USC
Automated construction in Japan
• 89 single task construction robots
• 11 different automated construction systems
Concrete Surface Treatment Robot
This robot absorbs the water which remains after concrete has been set.
Viterbi School of Engineering .
USC
Big-Canopy high-rise pre-cast concrete construction system. Used to construct the 26 storey pre-cast concrete 30,726m2 Yachiyodai Condominium building in Japan. The system realized a 60% reduction in labor requirements for the frame erection.
Viterbi School of Engineering .
USC
Form work cost structure
Ties
Wales
Studs
Sheathing
Concrete footing
Brace
Reinforcement
53%30%
10% 7% Formwork Labor
Concrete Materials
Formwork Materials
Concrete Labor
Viterbi School of Engineering .
USC
Adobe structures – Ageless comfort and beauty
House of Brojerdi Kashan
Viterbi School of Engineering .
USC
House made with vaults and domes
Interior of an Adobe house CalEarth Design
Viterbi School of Engineering .
USC
Ingenious methods
Manual construction of adobe form structures using clay bricks (Source: Khalili, 2000)
A vault structure made of clay bricks (Source: Khalili, 2000)
Viterbi School of Engineering .
USC
What constitutes construction cost?
Portion Due to If Automated by CC
20%-25% Financing Short project length and control of
time to market will dramatically reduce this cost
25%-30% Materials Will be a wasteless (lean) process
45%-55% Labor Will be significantly reduced
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