Technology developments are changing the experience of traveling by plane, how railway infrastructure can be leveraged to generate energy, and even the possibility of building homes on Mars. The field of architecture is about to see major changes thanks to ’Large-scale additive manufacturing’, or 3D-printing buildings.
According to the World Economic Forum (WEF), construction materials have been confined to a range of mass-produced elements since the dawn of the industrial revolution. From steel beams to plywood panels, these elements have shaped the design and construction of buildings for over 150 years.
Not since the adoption of the steel frame has there been a development with as much potential to transform the way buildings are conceived and constructed as there is now with Large-scale additive manufacturing, according to the director of the Institute for Smart Structures, University of Tennessee, James Rose.
Large-scale additive manufacturing, like desktop 3D printing, involves building objects one layer at a time. Whether it’s clay, concrete or plastic, the print material is extruded in a fluid state and hardens into its final form. Despite some roadblocks to the widespread adoption of this technology, Rose foresees a future in which buildings are built entirely from recycled materials or materials sourced on-site, with forms inspired by the geometries of nature.
1. Understanding the process
Large-scale additive manufacturing involves three knowledge areas: digital design, digital fabrication and material science. Architects first create computer models of all the components that will be printed. These designers can then use software to test how the components will respond to structural forces and tweak the components accordingly.
These tools can also help the designer figure out how to reduce the weight of components and automate certain design processes, such as smoothing complex geometric intersections, prior to printing. A piece of software known as a slicer then translates the computer model into a set of instructions for the 3D printer.
Advances in 3D printing technology have allowed the hardware to scale up in a serious way. Sometimes the printing is done via what’s called a gantry-based system – a rectangular framework of sliding rails similar to a desktop 3D printer. Increasingly, robotic arms are used due to their ability to print in any orientation.
Furnishings and smaller components can be printed in factories, while entire houses must be printed on-site. A range of materials can be used for large-scale additive manufacturing. Concrete is a popular choice due to its familiarity and durability. Clay is an intriguing alternative because it can be harvested on-site.
According to the WEF, plastics and polymers could have the broadest application. These materials are incredibly versatile, and they can be formulated in ways that meet a wide range of specific structural and aesthetic requirements. They can also be produced from recycled and organically derived materials.
2. Other advantages
An interesting feature of large-scale additive manufacturing is the capability to produce components with internal voids. An instance where this could prove useful is a wall printed with conduit or ductwork already in place.
According to Rose, research is taking place to explore the possibilities of multi-material 3D printing, a technique that could allow windows, insulation, structural reinforcement, even wiring, to be fully integrated into a single printed component.
When building layer by layer, it opens up windows of opportunity, allowing designers to implement geometries that are difficult to produce using other construction methods, but are common in nature.
Structural frames inspired by the fine structure of bird bones could create lightweight lattices of tubes, with varying sizes reflecting the forces acting upon them. Façades that evoke the shapes of plant leaves might be designed to simultaneously shade the building and produce solar power.
