USC Mega-Scale Fabrication by Contour Crafting Behrokh Khoshnevis University 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 Commercialized 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 Side trowel control mechanism CC is a layered fabrication method which combines ancient surface forming concepts with modern robotics Nozzle technology Top trowel Side trowel Viterbi School of Engineering .
USC A CC machine for thermoplastics Viterbi School of Engineering .
USC Nozzle Assemblies Viterbi School of Engineering .
USC Plastic Parts 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 Building Various Surface Slopes Viterbi School of Engineering .
USC Slant Wall Fabrication Viterbi School of Engineering .
USC Creating hollow depositions Viterbi School of Engineering .
USC Embedding Reinforcement Viterbi School of Engineering .
USC Application in Construction 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 Non-farm productivity index Construction Productivity index Labor productivity comparison for non-farm industries and construction industry developed by Paul Teicholz 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 This robot absorbs the water which remains after concrete has been set. Concrete Surface Treatment Robot Viterbi School of Engineering .
USC Big-Canopy high-rise pre-cast concrete construction system. Used to construct the 26 storey pre-cast concrete 30, 726 m 2 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 Viterbi School of Engineering .
USC A straight wall builder Viterbi School of Engineering .
USC Full scale wall sections Viterbi School of Engineering .
USC Viterbi School of Engineering .
USC Viterbi School of Engineering .
USC Adobe structures – Ageless comfort and beauty House of Brojerdi Kashan Viterbi School of Engineering .
USC Interior of an Adobe house Cal. Earth Design Viterbi School of Engineering .
USC House made with vaults and domes Interior of an Adobe house Cal. Earth 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 Free-standing Objects / Industrial parts Viterbi School of Engineering .
USC Adobe house Construction Viterbi School of Engineering .
USC Extraterrestrial Construction Viterbi School of Engineering .
USC Deployable CC Viterbi School of Engineering .
USC Lunar Construction Viterbi School of Engineering .
USC Machine at NASA Viterbi School of Engineering .
USC Viterbi School of Engineering .
USC Viterbi School of Engineering .
USC Viterbi School of Engineering .
USC Next Machine Viterbi School of Engineering .
USC Viterbi School of Engineering .
USC Research specimens (concrete) Viterbi School of Engineering .
USC Please visit www. Contour. Crafting. org 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 Viterbi School of Engineering .
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