3D AFFORDABLE INNOVATIVE TECHNOLOGIES HOUSING PROJECT_(YanJiu Bai's part)

3D AFFORDABLE INNOVATIVE TECHNOLOGIES HOUSING PROJECT

Iowa State University College of Design Research Report 2022-24

00.Project Introduction

Introducing AIT Project Goals + Objectives

This project will help address an a ordable housing shortage with advanced technologies like 3D Construction Printing, which is happening now in a few select markets in the US — with claimed improvements of 2-3x faster construction, more reductions in labor costs, site waste and material usage.

Additionally, we are going to look at other technologies, some which you may already be familiar with. Like IKEA’s kitchen design website. We aim to advance this user-centered idea further — for the 3D A ordable Innovative Technologies (3D AIT) housing project.

Examples of these emerging technologies that we aim to integrate include Geographic and Geospatial Information Systems, building information & energy modeling, radar and lidar, onsite robotics, telepresence, virtual and extended reality, and advanced web standards for a digital project delivery solution. We will be applying these capabilities toward a demonstration project in Hamburg, IA with Brunow Construction.

This project is a comprehensive review of a 20th century legacy to a 21st century opportunity to transform a ordable housing. We do that with many Iowa partners and stakeholders — and would highlight Iowa Central Community College. This collaboration will look at ways these technologies can be developed into a new technical curriculum (both formally and informally) for workforce development - re-skilling, up-skilling and scaling this program across IA to advance a sustainable 21st century housing industry and to address the need for a ordable housing here in Iowa.

08.Cement 3d Printing & Modeling

Testing at Scale

The ISU Comptuation and Construction Lab is home to 4 Potterbot desktop scale printers. Over the past five years the lab has developed a series of scripts and wor lows for printing clay and is now applying this research to printing desktop scale cement mortar models to explore the possibilites of 3D printing concrete at full scale.

A cast cement model is made to replicate scaled prints. The 3d printed frame, in pink, is deconstructed after drying.

Scale Concrete Printing

This research began with a paper by colleagues in ISU Construction Engineerig department:

Kwangwoo Wi, Kejin Wang, Peter C. Taylor, Simon Laflamme, Sri Sritharan, Hantang Qin, Properties and microstructure of extrusion-based 3D printing mortar containing a highly flowable, rapid set grout,

Cement and Concrete Composites, Volume 124.

Testing scale 3D prints with the Potterbot using a custom printing mix from ISU Construction Engineering

Printing Process

Example of a 3D PotterBot 10 PRO

Source: 3dpotter.com/printers Diagram of printing process

to the Machine and Check the Z Axis

and Clean Extra Clay

Printing Results

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 24mm/s (80%)

Extrusion Factors: 150%

Concrete Recipe:

VMA : (Cement+Grout) Water

186.7 (500 + 166.7) 10

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 15mm/s (30%)

Extrusion Factors: 150%

Concrete Recipe:

VMA (Cement+Grout) Water

186.7 (500 + 166.7) 10

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 21mm/s (70%)

Extrusion Factors: 150%

Concrete Recipe:

VMA : (Cement+Grout) Water

186.7 (500 + 166.7) 10

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 17mm/s (55%)

Extrusion Factors: 160%

Concrete Recipe=

VMA : (Cement+Grout) Water

186.7 (500 + 166.7) 10

Feedback(Failiures/Success):

The speed was too fast. Air bubbles made the printing process not consistent. Mixing cement also was not good enough.

Feedback(Failiures/Success): The speed was too slow. Air bubbles made the printing process not consistent.

Feedback(Failiures/Success):

The speed was questionable. Air bubbles became less, but the first layer didn’t build up nicely.

Feedback(Failiures/Success):

The speed was kind of good.The concrete became more condensed because the pressure from the machine could change the density of the concrete.It didn’t use all of the concrete in the printer because the condensed concrete had a hard time pushing out.

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 17mm/s (55%)

Extrusion Factors: 140%

Concrete Recipe=

VMA : (Cement+Grout) Water

280 : (750 + 250) : 15

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 17mm/s (55%)

Extrusion Factors: 150%

Concrete Recipe=

VMA : (Cement+Grout) Water

280 : (750 + 250) : 15

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 18 mm/s (60%)

Extrusion Factors: 140%

Concrete Recipe=

VMA : (Cement+Grout) Water

280 : (750 + 250) : 15

Feedback(Failiures/Success): The speed was good. The concrete was too wet.

Feedback(Failiures/Success):

The speed was good. Air bubbles made terrible layers of the beginning parts.

Feedback(Failiures/Success):

The speed was good. The concrete was better than before. The consistency was still the problem.

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 18 mm/s (60%)

Extrusion Factors: 130%

Concrete Recipe=

VMA : (Cement+Grout) Water

280 : (750 + 250) : 15

Feedback(Failiures/Success):

After printing in prime file for a while, the concrete became more consistent. The speed and extrusion factor was in a great ratio for a 6mm nozzle. However, it failed o when the print reached a certain height.

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 18 mm/s (60%)

Extrusion Factors: 130%

Concrete Recipe=

VMA : (Cement+Grout) Water

280 : (750 + 250) : 15

Dim (W x D x H): 65 x 90 x 25

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 18 mm/s (60%)

Extrusion Factors: 135%

Concrete Recipe=

VMA : (Cement+Grout) Water

280 : (750 + 250) : 15

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 18 mm/s (60%)

Extrusion Factors: 135%

Concrete Recipe=

VMA : (Cement+Grout) Water

280 : (750 + 250) : 15

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 18 mm/s (60%)

Extrusion Factors: 130%

Concrete Recipe=

VMA : (Cement+Grout) Water

280 : (750 + 250) : 15

Nozzle Size (Diameter): 6mm

Layer Height: 1mm

Speed: 21mm/s (70%)

Extrusion Factors: 140%

Concrete Recipe:

VMA : (Cement+Grout) Water

280 : (750 + 250) : 15

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 18 mm/s (60%)

Extrusion Factors: 140%

Concrete Recipe=

VMA : (Cement+Grout) Water

280 : (750 + 250) : 15

Feedback(Failiures/Success):

The water dripping from pipes was changing some parts of the concrete. It still failed o when the print reached a certain height.

Feedback(Failiures/Success): The speed and extrusion factor was excellent for a 6mm nozzle. It still failed o when the print reached a certain height.

Feedback(Failiures/Success): It still couldn’t avoid to wast the remaining concrete in the pipe. The design of Potterbot caused an unavoidable problem: the density of concrete will increase after printing for a while.

Feedback(Failiures/Success): print in a testing file, so it can use less layer height to test the model. It was standable.

Feedback(Failiures/Success): print in a testing file, so it can use less layer height to test the model. It stood.

Feedback(Failiures/Success): It is printed with not enough concrete.

Printing Results

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 18 mm/s (60%)

Extrusion Factors: 140%

Concrete Recipe=

VMA : (Cement+Grout) : Water 280 (750 + 250) 15

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 18 mm/s (60%)

Extrusion Factors: 135%

Concrete Recipe=

VMA : (Cement+Grout) : Water 280 (750 + 250) 15

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 21 mm/s (68%)

Extrusion Factors: 135%

Concrete Recipe=

VMA : (Cement+Grout) Water

280 : (750 + 250) : 15

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 20 mm/s (65%)

Extrusion Factors: 135%

Concrete Recipe=

VMA : (Cement+Grout) : Water

280 (750 + 250) 15

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 20 mm/s (65%)

Extrusion Factors: 135%

Concrete Recipe=

VMA : (Cement+Grout) : Water

280 (750 + 250) 15

Nozzle Size (Diameter): 6mm

Layer Height: 1mm

Speed: 15mm/s (50%)

Extrusion Factors: 100%

Concrete Recipe:

VMA : (Cement+Grout) : Water

280 : (750+250) 20

Feedback(Failiures/Success):

Try to retest whether the layer’s height of other factors a ects the result.

Nozzle Size (Diameter): 6mm

Layer Height: 1.5mm

Speed: 20mm/s (66%)

Extrusion Factors: 130%

Concrete Recipe:

VMA : (Cement+Grout) : Water

280 : (750+250) 20

Feedback(Failiures/Success):

Try to retest whether the layer’s height of other factors a ects the result. Adjust printing speed.

Feedback(Failiures/Success):

The block almost stood but fell o at a certain height during printing corners. was questing whether the round corner would a ect the stability.

Feedback(Failiures/Success):

The block almost stood but fell o at a certain height during printing corners. tried again. Although the concrete quality wasn’t good, it still fell o in a similar situation.

Feedback(Failiures/Success):

The concrete quality wasn’t good.

Feedback(Failiures/Success):

I chose a di erent shape to test whether the form of modeling a ects the print result. The form and rounder corner would a ect the stability of the model on this scale. Also, add more VMA to increase the stability of the components in cement.

Feedback(Failiures/Success):

After changing VMA, I reprint it again, and the result becomes better.

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 20mm/s (66%)

Extrusion Factors: 133%

Concrete Recipe:

VMA : (Cement+Grout) Water

280 : (750+250) 20

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 20mm/s (66%)

Extrusion Factors: 135%

Concrete Recipe:

VMA : (Cement+Grout) : Water 280 : (750+250) 20

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 20mm/s (66%)

Extrusion Factors: 130%

Concrete Recipe:

VMA : (Cement+Grout) : Water

280 : (750+250) 20

Feedback(Failiures/Success): After changing the corner from round to sharp, the print stood!

Nozzle Size (Diameter): 4.5mm

Layer Height: 2.25mm

Speed: 18mm/s (60%)

Extrusion Factors: 130%

Concrete Recipe:

VMA : (Cement+Grout) : Water

280 : (750+250) 20

Nozzle Size (Diameter): 4.5mm

Layer Height: 2.25mm

Speed: 18mm/s (60%)

Extrusion Factors: 130%

Concrete Recipe:

VMA : (Cement+Grout) : Water

280 : (750+250) 20

Feedback(Failiures/Success): I reprint again. The shift of the base caused it collapses.

Feedback(Failiures/Success): The shift of the base caused it collapses.

Nozzle Size (Diameter): 4.5mm

Layer Height: 2.25mm

Speed: 18mm/s (60%)

Extrusion Factors: 130%

Concrete Recipe:

VMA : (Cement+Grout) : Water

280 : (750+250) 20

Nozzle Size (Diameter): 3mm

Layer Height: 1.5mm

Speed: 18mm/s (60%)

Extrusion Factors: 130%

Concrete Recipe:

VMA : (Cement+Grout) : Water 280 : (750+250) 20

Feedback(Failiures/Success): Test out the half floor plan on a 1/4” scale. Fell o because air bubble.

Feedback(Failiures/Success): The print was great to a certain height. It was stopped before falling o .

Feedback(Failiures/Success): The wall would fall o , reaching certain even if the form changed.

Feedback(Failiures/Success): Changing the layer height didn’t change a lot.

Printing Results

Nozzle Size (Diameter): 4.5mm

Layer Height: 2.25mm

Speed: 18mm/s (60%)

Extrusion Factors: 130%

Concrete Recipe:

VMA (Cement+Grout) Watebv 280 (750+250) 20

Nozzle Size (Diameter): 4.5mm

Layer Height: 2.25mm

Speed: 18mm/s (60%)

Extrusion Factors: 130%

Concrete Recipe:

VMA (Cement+Grout) Water 280 (750+250) 20

Nozzle Size (Diameter): 4.5mm

Layer Height: 2.25mm

Speed: 18mm/s (60%)

Extrusion Factors: 130%

Concrete Recipe:

VMA (Cement+Grout) Water 280 (750+250) 20

Nozzle Size (Diameter): 3mm

Layer Height: 1.5mm

Speed: 18mm/s (60%)

Extrusion Factors: 130%

Concrete Recipe:

VMA (Cement+Grout) Water 280 (750+250) 20

Nozzle Size (Diameter): 3mm

Layer Height: 1.5mm

Speed: 18mm/s (60%)

Extrusion Factors: 130%

Concrete Recipe:

VMA (Cement+Grout) Water 280 (750+250) 20

Nozzle Size (Diameter): 3mm/6mm

Layer Height: 1.5mm/3mm

Speed: 18mm/s (60%)

Extrusion Factors: 130%

Concrete Recipe:

VMA (Cement+Grout) Water 280 (750+250) 20

Feedback(Failiures/Success):

Printing the whole floor plan is taught. It was hard to get clear corners when moving from one wall to another.

Printing Results

Feedback(Failiures/Success): Print walls separately can get clean ends.

Feedback(Failiures/Success): Sometimes, the unclear base would influence the wall’s straightness.

Feedback(Failiures/Success): Short walls had a hard time printing.

Feedback(Failiures/Success): A T-shape layout also could be a challenge to print.

Feedback(Failiures/Success): Put all walls together. Short walls and complicated connections still make it hard to print.

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 18mm/s (60%)

Extrusion Factors: 110%

Concrete Recipe:

VMA (Cement+Grout) Watebv 280 (750+250) : 20

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 18mm/s (60%)

Extrusion Factors: 110%

Concrete Recipe:

VMA (Cement+Grout) Water 280 (750+250) : 20

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 18mm/s (60%)

Extrusion Factors: 130%

Concrete Recipe:

VMA (Cement+Grout) Water 280 (750+250) : 20

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 18mm/s (60%)

Extrusion Factors: 130%/120%/110%

Concrete Recipe:

VMA (Cement+Grout) Water 280 (750+250) : 20

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 18mm/s (60%)

Extrusion Factors: 130%

Concrete Recipe:

VMA (Cement+Grout) Water 280 (750+250) : 20

Nozzle Size (Diameter): 6mm

Layer Height: 3mm

Speed: 18mm/s (60%)

Extrusion Factors: 130%

Concrete Recipe:

VMA (Cement+Grout) Water 280 (750+250) : 20

Feedback(Failiures/Success): Walls fall o because the print base moved.

Feedback(Failiures/Success): The base wasn’t clean and caused the wall to fall o

Feedback(Failiures/Success): When the wall became thinner, it would a ect water vaporation and cause a crack.

Feedback(Failiures/Success): It stands up.

Feedback(Failiures/Success):

Feedback(Failiures/Success):