Nov 14, 2015 | By Benedict
3D printing has long been earmarked as the future of construction. In Amsterdam, for example, a project is underway to build the world’s first 3D printed canal house. However, few additive construction projects have sought to combine 3D printing technology with traditional concrete building. Alex Le Roux, a mechanical engineering student who built his own concrete 3D printer earlier this year, leads one of those few projects. Following his initial model, Le Roux has returned with a new version of his unique machine. A student at Baylor University, Texas, Le Roux previously built an 8’ x 8’ x 8’ concrete 3D printer, using open-source RepRap components. That initial model was built to enable the 3D printing of concrete structures for housing purposes, and the student’s upgrade fulfils a similar purpose.
"A lot of the tough engineering problems were solved with this first concrete 3D printer,” explained Le Roux back in July. “For example, and most specifically, the ingredients of the concrete mixture, the extruder design, and the electronics to support such a massive machine.” That 3D printer was able to print at layer heights of .75cm, an impressive figure considering the material used, and Le Roux’s latest model boasts a range of new features and upgrades.
Perhaps most significantly, Version 2 of the concrete printer provides a 10’ x 10’ x 10’ build volume, allowing for huge concrete 3D prints. As well as being able to 3D print component blocks for later assembly, the large build area enables the 3D printing of “Tiny house” structures: complete, single-print constructions.
The printer itself retains its RepRap core, and can be assembled by users in approximately 30 minutes. This makes it extremely convenient for construction workers to operate, since printing can begin immediately after another 30 minutes of concrete mixing has elapsed.
Readers may still doubt the utility of a concrete 3D printer. Most 3D printers are housed in an office or laboratory, with their small and lightweights prints easily transported afterwards. But many would be reluctant to transport 10 cubic feet of concrete from their office to a construction site. Naturally, Le Roux has thought all of this through, and designed the 3D printer to be rain proof, meaning it can be used outdoors on construction sites. The electronic components of the concrete printer are shielded from external interference, making it safe and convenient to use in conventional construction settings.
As well the larger build area and weather resistance, the second version of Le Roux’s 3D printer is packed with improved electronic hardware. The latest model is able to print at speeds upwards of 1 foot per second on the X/Y plane, and its concrete flow rates have been massively improved. The new machine boasts a flow rate of 4 litres per second.
Le Roux and his team are currently considering outside investment in their product, and are open to approaches from interested individuals and companies.
Posted in 3D Printer
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I have seen similar printers that string out steel wire that embeds in the concrete as it prints to add tensile strength.
Tom S wrote at 11/24/2015 9:52:03 PM:
You're right; concrete is terrible in tension. So design your stuff for compression, which concrete excels at. Also, you could lay down a pass or two, then add the rebar manually, and then continue the extrusion. I'm thinking of a beam, for example. Stop again when the next rebar is needed, and add it. Feasible? Perhaps new rebar could be made from flat, rather than round. It would still need the upsets, for the concrete to grab, but would lend itself to your method quite well. Keep up the good work! Very impressive. Aren't the Chinese doing something like this?
bubba wrote at 11/18/2015 6:29:36 PM:
By using either HPC (High Performance Concrete), or UHPC (Ultra High Performance Concrete), the need for rebar could be eliminated. Could be a very interesting future for concrete structure building design...
Stupid and Industrious wrote at 11/17/2015 5:47:44 PM:
ADD A REBAR BENDING EXTRUDER OF COURSE! HONESTLY BENDING TECHNOLOGY WOULDN'T BE AN EXPENSIVE ADDITION, BUT MAINTAINING TOLERANCE BETWEEN THE TWO COULD BE DIFFICULT ON A BUDGET. THE FEED MECHANISM MAY ALSO PROVIDE PROBLEMATIC AS I'M VISUALIZING SOMETHING SIMILAR TO A HDD RIG BEING FRAME MOUNTED. SEEING THE SCHEDULE 40 PVC ON THE CONCRETE EXTRUDER WAS A NICE TOUCH. SOME HIGHGLOSS BLACK WOULD HAVE TAKEN AWAY THE BUDGET MINDED NATURE OF THE PROJECT. KEEP IT UP. Sorry for the all caps, too lazy to retype.
Martin wrote at 11/16/2015 8:24:05 PM:
I like the idea, but with all of these concrete printers, I have to wonder about their end-use strength. In most concrete structures I see these days, rebar is added to provide tensile strength (concrete has very little). How would this machine allow for the addition of rebar?
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