Essay: Additive manufacturing in the construction industry

1.1 Motivation and purpose
This report is written as a specialization report in the 7th Semester Bachelor of Architectural Technology and Construction Management course at Copenhagen School of Design and Technology.
This report is made to find an appropriate topic that fits my education. I have since the beginning of my study, been very interested in 3D printing and often used it to visualize my 3D models. Therefore, it has been a good addition to physical models.
When it comes to 3D printing, thoughts often tend towards the endless opportunities to build and create things and shapes that were previously impossible
I would like to take the reader from the very beginning to today. Then explore what the future holds and what opportunities it has.
1.2 Research Question
In order to guide my investigation about additive manufacturing in the construction industry, I have formulated the following research question:
Are there buildings already made with this technique?
What does the future brings?
1.3. Introduction to Research about additive manufacturing.
The research carried out in the report will be based on the data found in books and on the internet, as well as information given by the supervisors and experts.
Since this subject is still under studies and development, there will be a challenge to find answers to all the questions. By using both primary and secondary data, I will try to research as much as I can and go into the existing case studies, take interviews and come up with a conclusion where I can provide all the answers.
2. Theory
In this chapter, the theoretical framework for my research methodology and analysis will be outlined.
Additive manufacturing (AM) is sometimes referred to as 3D printing (3DP), as parts are built up by adding layers of material on top of each other.
These new techniques, while still evolving, are expected to have a major impact on manufacturing. They can give industry new design flexibility, reduce energy use, and shorten time to market.
2.1 The history of 3D printing
An American engineer Charles Hull developed the first 3D printer in 1984. He had been studying photopolymers, plastics that can be hardened with light, when the idea struck him to build a device that would allow the user to harden a thin layer of plastic after another, gradually building a desired object.
Charles Hull invents stereolithography (SLA) — which is patented in 1987. The technology allows you to take a 3D model and use a laser to etch it into a special liquid (photopolymer).
In 1991 the company Stratasys produces the world’s first FDM (Fused deposition modelling) machine. This technology uses plastic and an extruder to deposit layers on a print bed. In 1992, Charles Hull and his company 3D systems produce the first 3D printer machine. Hull founded 3D Systems in 1986, which is still the largest manufacturer of 3D printers. 3D systems produce the first 3D Printing machine. (Wohlers, 2015)
Massachusetts Institute of Technology (MIT) patented another technology, named “3 Dimensional Printing techniques”, which is similar to the inkjet technology used in 2D Printers. In 2002 Scientists engineer a miniature functional kidney that is able to ¬lter blood and produce diluted urine in an animal.
MakerBot Industries, an open-source hardware company for 3D printers, starts selling DIY kits that allow buyers to make their own 3D printers and products, this really changes the 3D printing industry.
In 2011 Engineers at the University of Southampton design the world’s ¬first 3D-printed aircraft. This unmanned aircraft was built in seven days. 3D printing allows the plane to be built with elliptical wings, a normally expensive feature that helps improve aerodynamic efficiency and minimizes induced drag.
Doctors and engineers in the Netherlands use a 3D printer to print a customized three-dimensional prosthetic lower jaw, which is implanted into an 83-year old woman suffering from a chronic bone infection. This technology is currently being explored to promote the growth of new bone tissue.
The Dutch design company, MX3D have developed computer guided robotic arms tipped with welders to 3D print a steel bridge in midair over a canal in Amsterdam. The robots print using steel, stainless steel, aluminum, bronze, or copper. They make lines in the air, without the need for support structures. The machine even print a track to move alongside the bridge, while its being build.
Figure 2 – 3D printed bridge (prototype)
2.2 How 3D print works
It all starts with a concept. The first stage of 3D printing is laying out an original idea with digital modeling.
It does not matter what program you choose, you are able to create a virtual blueprint of the object you want to print. The program then divides the object into digital cross-sections so the printer is able to build it layer by layer. The cross-sections essentially act as guides for the printer, so that the object is the exact size and shape you want.
Once you have a completed design, you send it to the 3D printer with the standard file .STL (Stereolithographic)
STL files contain three-dimensional polygons that are sliced up so the printer can easily recognize its information.
Figure 3 Additive manufacturing (AM) process flow
After the finished design file is sent to the 3D printer, you choose a specific material. This, depending on the printer, can be rubber, plastics, paper, polyurethane-like materials, metals and more.
Printer processes vary, but the material is usually sprayed, squeezed or otherwise transferred from the printer onto a platform.
Then, a 3D printer makes passes (like an inkjet printer) over the platform, putting layer on top of layer of material to create the finished product. This can take several hours or days depending on the size and complexity of the object. The average 3D-printed layer is approximately 100 microns (or micrometers), which is the same as 0.1 millimeters. Some printers can even deposit layers as thin as 16 microns. (Counci, 2013)
2.3 Types of 3D printers:
There are different 3D printing methods to build 3D structures and objects.
2.3.1 Stereolithography(SLA)
Figure 4 Process of Stereolithography(SLA)
This method is the oldest one in history of 3D printing, but it is still being used. The idea of this method is amazing. Charles Hull, co-founder of 3D Systems patented this method. The process of printing involves a uniquely designed 3D printing machine called a stereolithograph apparatus (SLA), which converts liquid plastic into solid 3D objects.
The process of printing includes several steps. It starts from creation of 3D model in CAD program, special piece of software processes the CAD model and generates STL file that contains information for each layer. There could be up to ten layers per each millimeter. Then SLA machine exposes the liquid plastic and laser starts to form the layer of the item.
The time required to print an object depends on size of SLA 3d printers used. Small items can be printed within 6-8 hours with small printing machine, big items can be several meters in three dimensions and printing time can be up to several days long.
Stereolithography is widely used in prototyping as it doesn’t require too much time to produce an object and cost is relatively cheap comparing to other means of prototyping. This 3D printing method is rarely used for printing of the final product. (budmen, 2013)
2.3.2 Fused deposition modeling (FDM)
Figure 5 Process of Fused deposition modeling (FDM)
Fused deposition modeling (FDM) technology was developed and by Scott Crump, founder of Stratasys in 1980s. With help of FDM you can print not only functional prototypes, but also concept models. What is good about this technology that all parts printed with FDM can go in high-performance thermoplastic, which is very beneficial for mechanic engineers and manufactures.
FDM is the only 3D printing technology that builds parts with production-grade thermoplastics, so things printed are of excellent mechanical, thermal and chemical qualities. The whole process is a bit similar to stereolithography.
Printing time depends on size and complexity of an object printed. Small objects can be competed relatively quickly while bigger or more complex parts require more time. Comparing to stereolithography this technique is slower in processing. When printing is completed support materials can easily be removed either by placing an object into a water or snapping the support material off by hand.
This technology is considered to be simple-to-use and environment-friendly. With use of this 3d printing method it became possible to build objects with complex geometries. (budmen, 2013)
2.3.3 Selective Laser Sintering (SLS)
2.3.4 Other 3D printing methods
Electronic Beam Melting (EBM) another type of additive manufacturing for metal parts. EBM uses an electron beam. The rest of the processes is similar as the systems mentioned above. The material used in EBM is metal powder that melts and forms a 3D part layer by layer. The process is usually conducted under high temperature up to 1000 °C. The process of EBM is rather slow and expensive; the availability of materials is limited. Therefore, the method is not so popular though still used in some of manufacturing processes.
Laminated object manufacturing (LOM) is one more rapid prototyping system that was developed by the California-based company Helisys Inc.
During the LOM process, layers of adhesive-coated paper, plastic or metal laminates are fused together using heat and pressure and then cut to shape with a computer controlled laser or knife.
Probably LOM is not the most popular 3D printing method but one of the most affordable and fastest. The cost of printing is low due to not expensive raw materials. Objects printed with LOM can be relatively big, that means that no chemical reaction needed to print large parts. (budmen, 2013)
2.4 Materials
Figure 7 – Many different materials is possible these days.
The materials available for 3D printing have come a long way since the early days of the technology. There is now a wide variety of different material types, that are supplied in different states (powder, filament, pellets, granules, resin etc).
However, there are now way too many materials from the many different 3D printer to cover them all.
2.4.1 Plastics
Nylon, or Polyamide, is commonly used in powder form with the sintering process or in filament form with the FDM process. It is a strong, flexible and durable plastic material that has proved reliable for 3D printing. It is naturally white in color but it can be colored. This material can also be combined with powdered aluminum to produce another common 3D printing material called Alumide.
ABS is another common plastic used for 3D printing, and is widely used on FDM 3D printers in filament form. It is a particularly strong plastic and comes in a wide range of colors. ABS can be bought easily, which is another reason why it is so popular.
PLA is a biodegradable plastic material. It is offered in a variety of colors, including transparent, which has proven to be a useful option for some applications of 3D printing. However it is not as durable or as flexible as ABS.
LayWood is a specially developed 3D printing material for 3D printers. It comes in filament form and is a wood/polymer composite.
2.4.2 Metals
A growing number of metals and metal composites are used for 3D printing. Two of the most common are aluminium and cobalt.
One of the strongest and therefore most commonly used metals for 3D printing is Stainless Steel in powder. It is naturally silver, but can be plated with other materials to give a gold or bronze effect.
In the last couple of years Gold and Silver have been added to the range of metal materials that can be 3D printed directly, with obvious applications across the jewellery sector. These are both very strong materials and are processed in powder form.
Titanium is one of the strongest possible metal materials and has been used for 3D printing industrial applications for some time.
2.4.3 Ceramics
Ceramics are a relatively new group of materials that can be used for 3D printing with various levels of success. The particular thing to note with these materials is that, before printing, the ceramic parts need to undergo the same processes (firing and glazing) as any ceramic part made using traditional methods of production.
2.4.4 Paper
3D printed models made with paper are safe, environmentally friendly, easily recyclable and require no further finishing.
2.4.5 Bio Materials
There is a huge amount of research being conducted into the potential of 3D printing bio materials. Living tissue is being investigated at a number of leading institutions with a view to developing applications that include printing human organs for transplant, as well as external tissues for replacement body parts.
2.4.6 Food
Experiments with extruders for 3D printing food substances has increased dramatically over the last couple of years. Chocolate is the most common. There are also printers that work with sugar and some experiments with pasta and meat.
2.5 Introduction to 3D printing in architecture.
3D modeling in architecture has primarily been for visualization and rendering purposes. 3D printing requires a solid model, which needs geometric surfaces that properly fit together. All six sides of a cube need to be modeled even if one or more of the sides will be embedded within another solid fill object.
For many architects the design stage begins and ends in two-dimensions. To create 3D prints we need to reconstruct the original 2D design as a 3D model. If you are an architect or working with an architect that is using 3D software to visualize designs, then you are off to a good start and 3D printing may very well be a matter of minor preparation and a few workflow changes. For those who have not tried 3D modeling it may seem difficult. Fortunately, the process of generating a 3D file and print of an architectural concept is straightforward. There are many guides to getting started and it is possible to make for free. The people in the 3D printing industry, are very helpful and will assist you getting started. (Z Corporation; 2013)
2.6 Additive manufacturing in the building industry
In the early days of 3D printing, there was much talk of how it would transform the building industry. How this new tool would help skyscrapers to be erected without the need for teams of builders, scaffolding and cranes. Health and safety would be a thing of the past, in a world where robots did all the heavy lifting. Yet for all its optimism about its potential to construct entire buildings, 3D printing had mostly only been used to produce small-scale objects
Within the fields of engineering and industrial design, the shift from prototyping towards manufacturing was mainly driven by improvements in materials. (Olcayto,2014)
The step from prototype to actual manufactured object is rather small once the material properties of additive fabrication technology improved. This shift is much more difficult when we try to build architecture instead of architectural models through additive fabrication. Scale is one of the main differences between industrial design and architecture. Architects are used to work at scale. Drawings and models are always a scaled representation of the actual architectural design. The scale of architectural models can easily range between anything from 1:5 to 1:1000. There will need to be a massive scaling exercise to use additive fabrication as a construction technology for buildings or building components. (DeKestelier; Foster+Partner)
Figure 8 History of architecture in models
Originally, architecture firms were among the first businesses to adopt 3D printing technologies to ease and simplify the creation of their architecture models. This important step between a conceptualized design and the first brick in the construction site helps architects to study the interaction of volumes and shapes, communicate design ideas, explore how a design looks from different perspectives, visualize light interactions and even the key phase of selling the design. Back in the old times and especially today with modern sophisticated designs, manual architecture modelling requires skilled craftsmanship and a enormous amount of time, so it is natural to evolve towards a faster, more accurate and easier option. (budmen, 2013)
2.6 Advantages of additive manufacturing(AM)
Overall, 3D printing offers companies time efficiencies and cost reductions throughout the product lifecycle, as well as greater flexibility in design and product customization than traditional manufacturing.
Easily transform sketches and model drawings (digital) to models.
Perfect tool for shape studies.
Models can be a valuable way of communicating ideas to colleagues as well as towards the client. Your client may not always be capable to read or understand 3D drawings created on a computer.
You will spend less time in the modeling space. Just turn on the 3D Printer and you can continue with other important work while your printer does all the work.
Since you save time on building the model by hand, you can spend more time on developing different concepts of the model.
3D printing can not only be used for sketch models, also presentation models can be printed to quickly pitch designs
The great thing of 3D Printing is that you are able to print complex shapes and highly detailed designs that will be too time consuming if they were build by hand.
A 3D Printer can be used to print detailed designs such as complex facades, interiors, environmental elements, roofs etc.
3D printing typically uses less material when manufacturing components, therefore it will reduce or eliminating scrap and waste during production. This makes 3d printing a more efficient process.
2.7 disadvantages of additive manufacturing(AM)
– Fewer manufacturing jobs
– Limited materials
– Expensive price for big pieces or mass production
– Copyright violation
– Dangerous items
– Size limitations
– Production of unnecessary stuff
3 Methods
3.1 Additve manufactoring and Global Effects
3D printing is already having an effect on the way that products are manufactured. The technology allows new ways of thinking.
One of the key factors behind this statement is that 3D printing has the potential to bring production closer to the people. The customization value of 3D printing and the ability to produce small production is a sure way to engage consumers.
Shipping spare parts and products from one part of the world to the other could potentially become outdated, as the spare parts might possibly be 3D printed on site. This could have a major impact on how businesses large and small operate in the future.
The aim for many consumers is to operate their own 3D printer at home, whereby digital designs of any product are available for download via the internet, and can be sent to the printer, which is loaded with the correct materials.
The wider adoption of 3D printing would likely cause reinvention of a number of already invented products, and of course, an even bigger number of completely new products. Today previously impossible shapes and geometries can be created with a 3D printer, but the journey has really only just begun. 3D printing is believed by many to have very great potential to growth into innovation and bring back local manufacturing. (Sher 2014)
Figure 9 Breakeven analysis comparing manufacturing processes
According to Deloitte University, the research concludes that additive manufacturing production, using a variety of materials, can provide an efficient alternative for low-to-medium-sized production runs. (Cotteleer, 2014) Figure 11 shows the breakeven curve between traditional manufacturing and additive manufacturing, meaning that additive manufacturing can by using a variety of different materials, provide an effective alternative to the low-to-medium-sized production.
3.2 Potential Effects to the Global Economy
The use of 3D printing technology has potential effects on the global economy, if adopted world wide. The shift of production and distribution from the current model to a localized production on site and customized production could potentially reduce the imbalance between export and import.
3D printing would have the potential to create new industries and completely new professions, such as those related to the production of 3D printers. There is an opportunity for professional services around 3D printing, ranging from new forms of product designers and printer operators.
The effect of 3D printing on the developing world. One example of the positive effect is lowered manufacturing cost through recycled and other local materials, but the loss of manufacturing jobs could hit many industries, which would take time to overcome.
The benefit perhaps the most from 3D printing, where the growing aged society and shift of age demographics has been a concern related to production and work force.
Also the health benefits of the medical use of 3D printing would cater well for an aging western society. (Sedghi;2015)
Figure 10 – Graph on the global 3D printing market value 2013-2018
3.3 Future of homes
From 3D printed structures of homes to innovative structural bricks that support advanced cooling and heating within homes, the rate of innovation for 3D printing has accelerated faster than anticipated. 3D printing is currently being applied to different parts of architecture, from nanoscale to full-scale units. In the Industrial Revolution, hand production methods was enough. Craft defined everything. The craftsman had an excellent knowledge of materials. There are significant opportunities that lie in architecture, but technology needs to evolve so that architectural elements that are composed of multiple materials can be printed for more efficient construction. (Dezeen;2015)
3.4 Saving the planet
The potentially most significant benefits of 3D printing may turn out to be environmental. Today oil and other resources are used to move products around the planet, with a great many things travelling hundreds or thousands of miles before they come into our possession. Given the increasing pressure on natural resource supplies and combat climate change, within a decade or two such mass transportation may be neither feasible or culturally acceptable.
3D printing is also potentially far more environmentally friendly than many forms of traditional industrial production. This is simply because it is based on ‘additive manufacturing’. In other words, while many traditional production techniques start with a block of material and cut, lathe, file, drill or otherwise remove bits from it in a subtractive fashion, 3D printing starts with nothing and adds only the material that the final object requires. Digital manufacturing using 3D printers can therefore result in raw material savings. (Barnatt, 2014)
When final product parts are 3D printed, manufacturers can also optimise their designs so that each part consumes the minimum of materials. 3D printed plastic or metal parts can, for example, be designed with internal air gaps or open lattice work that cannot be fabricated inside an object produced using traditional production techniques. Such a design approach also allows lighter parts to be created.
As a final environmental benefit, 3D printers may find significant application in the production of spare parts. Today, when most things break they cannot be mended as spares are simply not available. But with more and more 3D printers on hand, the opportunity will soon exist to fabricate whatever parts are needed to mend a great many broken things.
3D printing is also emerging as an energy-efficient technology that can provide environmental efficiencies in terms of both the manufacturing process itself, utilising up to 90% of standard materials, and, therefore, creating less waste.
Also throughout an additively manufactured product’s operating life, by way of lighter and stronger design that imposes a reduced carbon footprint compared with traditionally manufactured products. (Hoyle 2014)
3.5 Parametric design in 3D Printing
A brand new generation of architects and designers started using mathematical algorithms to show new aesthetic artifacts and shapes. In data-driven visualizations or parametric models for digital fabrication like 3D printing, in most cases, all roads will lead back to computational geometry. Computational geometry describes complex 3-dimensional forms and aesthetic processes in the form of mathematical algorithms as executable code. (Segerman, 2015)
Figure 11 – Achim Menges in collaboration with Steffen Reichert
Figure 13, shows a system called HygroScope. This climate-responsive composite material is comprised of maple veneer and synthetic composites. It responds to humidity in a such a way that the material appears to be “breathing”. The models are displayed in glass cases that can be programed to control the amount of humidity in the air, the composite materials then respond to these environments creating completely unique visual experiences.
3.6 Nano printing
Researchers from Vienna University of Technology have came up with a way to 3D print very precise on a nanoscale. The Eiffel Tower underneath Is 50 nanometer or 1600 times smaller then a human hair.
Nanotechnology can actually revolutionize a lot of electronic products, procedures, and applications. The areas that benefit from the continued development of nanotechnology when it comes to electronic products include nano transistors, nano diodes, OLED, plasma displays, quantum computers etc.
Nanotechnology can also benefit the energy sector. The development of more effective energy-producing, energy-absorbing, and energy storage products in smaller and more efficient devices is possible with this technology. Such items like batteries, fuel cells, and solar cells can be built smaller but can be made to be more effective with this technology. (Carlson; 2012)
3.6 4D Printing
To Break it down simply. 4D printing is when you print an object that can assemble itself.
Figure 12 Explanation of dimension in additive manufacturing terminology.
It is now an inflation of dimensions. If you go into an amusement park, you can find both 4D, 5D- and even 6D cinemas. The extra dimensions, posted notices can be movement of cinema chairs and water splashes. It is ridiculous, since there are only three spatial dimensions. Everything beyond this is for theoretical physicists and hot air sellers.
In the tangible, human reality however, there are four dimensions: width, depth, height – and time. Or transformation. It is this fourth dimension, which is used in the 4D printing, the materials: one 3D printing materials that on their own changing shape to a predetermined structure that is stored in the material itself. (Tibbits; 2014)
Figure 13 Provides the energy for the components inside to self-assemble.
It is the architect Skylar Tibbits, who along with his people at MIT has added an extra dimension to 3D printing. In fact he has recycled an idea known from nano research.
An example of a self-assembling structure is physically polio virus. When the virus is exposed to mechanical action, it goes into pieces. But the gathering again afterwards.
Skylar Tibbits have progressed nano physics to the human scale and have made materials that shape themselves to structures on the size of tennis balls.
An application for 4D printing could be structures to be used in extreme environments where it is too expensive or difficult to get to people. For example, in outer space, Arctic and other extreme environments.
4 Results and Analysis
After documenting about the history of 3D printing and the different techniques that can be used, I have a more clear idea about how 3D printers work, how they evolved and what are the main advantages and disadvantages.
3D printing has existed as a technology for about 30 years, but during the last few years, we have seen great progress in the field. Increasing attention with very creative and entrepreneurial people. There are still some critics, who obviously do not apply the increase of 3D printers.
The possibilities of 3D printing technologies are nearly limitless imagination, if anything is available in digital form, you can print it.
There is one big concern about the 3D printing future as lot of people are going to be left unemployed, but the reality is that a lot of new jobs can be created in this fields also.
Also the building industry can be a dangerous job, so having machines working instead of men can be a good idea, not just for safety reasons but also for accuracy and time saving.
I have made two interviews with people from 3D print industry who work with 3D printing. They have made me aware of some important aspects that I will take into consideration. (see appendix). There have been problems with printing in the correct scale. Many errors in printing and lacked guidance and information.
Both were very enthusiastic about the ability to print models for complex shapes
They were both very positive in terms of what the future holds.
I greatly appreciate their opinions and it has helped me to answer my main question.
5. Case studies — Exploring the territory of 3D printing in Architecture
5.1Cool bricks
The system, which was designed by Virginia San Fratello and Ronald Rael, works via evaporative cooling, based on the simple concept that water will evaporate if air with a lower dew point passes by. The dew point of the air is the temperature in which water vapor in that air condenses, forming a liquid. When the air temperature drops below the dew point, water droplets will begin leaving the air.
Based on this concept, the Cool Brick emerged.
Because the air in dessert environments is so hot and dry, and provides for the capability of holding a lot of water vapor, the cool brick could be the perfect solution. Made up with a 3D printed ceramic lattice, it can be filled with water in a similar way a sponge can. Then when hot, dry air passes through, the air absorbs the water through evaporation, and become cooler more moist air.
The bricks can be set into mortar to create walls of virtually any size. When these modular, interlocking bricks are stacked together, they create a large screen as seen in the photos provided. This could be a solution to the high electricity costs of running air conditioning systems in these hot, dry climates, killing two birds with one stone. A decorative looking cool brick wall could be constructed in a home, to cool that home off while also adding much needed moisture to the air. (Prindle; 2015)
Figure 14 – Uses nothing but water to cool homes in hot, dry climates
Figure 15 – – Process 3D printed ceramic “Cool Brick”
5.2 3D Printing in China
China-based WinSun Decoration Design Engineering Co. has already begun moving forward with 3D printing in architecture by producing 10 homes which were almost entirely 3D printed with a recycled concrete material in 2014. In their most recent accomplishment, they have printed apartment complexes up to 6 stories. According to WinSun, their 3D printing process for construction saves between 30 to 60 percent of waste that generally occurs and can decrease production times by 50 to 70 percent, and labour costs by between 50 to 80 percent.
Also a 3D-printed house has been built in just three hours in one of China’s capital cities. Chinese assembled the individual modules of a dining room, kitchen, bathroom and bedrooms. The modules were produced in a factory and then assembled on site. Despite its speedy construction, the engineer claims the building can withstand earthquakes because each module bears its own weight. Recently, a Chinese studio produced, The VULCAN pavilion, is a massive 23 meters long and 8 meters tall, leading the Guinness Book of World Records to label it the world’s largest 3D printed structure. Using 20 large-format 3D printers, the pavilion is composed of 1,023 individual parts, which were them assembled on-site. (Stott, 2014)
Figure 16 – 3D printing in China
Figure 17 – Process of tue making D-shape
5.4 Scale Model of Abu Dhabi
By nature, architectural modeling requires high-level craftsmanship and attention to detail. After building designs have been conceptualized and before ground is broken, real estate developers often transform their two-dimensional blueprints into three-dimensional scale models. The architecture for the model included multiple helix-shapes that needed to be both precise and strong because they were structural. (Stratasys; 2012)
Figure 18 – Complex 3D printedsScale Model of Abu Dhabi
5.5 3D printing in space
On-board the international space station (ISS), NASA made history by successfully 3D printing the first object in space. This first print serves to demonstrate the potential of the technology to produce replacement parts on demand if a critical component fails in space. (NASA;2015)
Figure 19 – 3D printing in space
5.5 My own experience with 3D printing
5.5.1 Case 1
Print date: 19/2 -2014
3D Printer: Wanhao – Dublicator 4 (FDM)
Price: 500 kr
Print time: 36 hours
Material: PLA plast
Rating from 1 to 5: 2
The first time I tried to 3D print an object was in my fourth semester. I had design consultancy, as an elective. We had been asked to make a scale model of our 3D model. We low a physical model in a scale of 1: 100 and decided to make a 3D print of a model in scale 1: 500, as it was the most Realistic in relation to time and price.
Then began a lot of research and came in contact with an open source workshop called FabLab. They told in depth about 3D printing and various processes.
However, they had no time to make a print for us.
We came in contact with a small firm in Vesterbro, they were very willing to help us with printing our object.
The result was okay without being impressive.
Figure 20 Process of 3D printing first attempt
5.5.2 Case 2
Print date: 5/5 -2015
3D Printer: Ultimaker 2 (FDM)
Price: When the school bought a Ultimaker 2, we were allowed to get the model free of charge
Print time: 8 hours
Material: PLA plast
Rating from 1 to 5:5
On our 5th semester, we made a very complex 3D model. Therefore, there was again need of a 3d printer. Through the school, we come into contact with 3dprinthuset in Copenhagen.
It was not entirely without problems. To print a 3D model, we had to use a solid fill model.
Since our model was built around wooden slats that spin around the core of the building. I had to make a mass model that fits all those adaptive components.
We made a nice model, which really shows the complexity of our building. Additionally, you really sense the shapes and curves in the 3D print.
Figure 21 process of 3D printing second attempt
6. Conclusion
After I completed my research, I can answer my main question:
How will additive manufacturing affect the building industry?
The complexity of structures and shapes that can be achieved is unlimited. This will give totally freedom to the architects and they will probably be the main factor of how the future buildings will look like.
3D printing has only been used on small scale projects in the construction industry and there are a lot of challenges that need to be dealt with prior to considering adopting it as one of the main construction technologies. For this type of technology to be successfully adapted by the construction industry, much further research has to be done.
The price of 3D printing is also problematic for large volumes, according to, and there are still limitations in terms of materials that can be used and the speed of the overall process.
3D printing will not replace the industrial process, but it will complement it. It will be used to produce some objects in a more dynamic and easy way.
Regardless of what direction 3D printing takes in the building industry, it is clear that it will change the building industry forever.
Figure 22 Illustration about additive manufactoring