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Mega-Scale Fabrication by Contour Crafting Behrokh Khoshnevis University of Southern California

Mega-Scale Fabrication by Contour Crafting Behrokh Khoshnevis University of Southern California. Fabrication Processes. Subtractive (milling, turning, chiseling, sawing,..) Formative (pressing, forging, bending,..) Additive Casting (requiring mold)

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Mega-Scale Fabrication by Contour Crafting Behrokh Khoshnevis University of Southern California

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  1. Mega-Scale FabricationbyContour CraftingBehrokh KhoshnevisUniversity of Southern California Viterbi School of Engineering .

  2. 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 .

  3. Commercialized RP Technologies Viterbi School of Engineering .

  4. Limitations of current SFF methods • Slow speed • Not scalable • Limited choice of materials • Impossible to embed other objects Viterbi School of Engineering .

  5. Material feed barrel Side trowel control mechanism Nozzle Top trowel Side trowel What is Contour Crafting? CCis a layered fabrication method which combines ancient surface forming concepts with modern robotics technology Viterbi School of Engineering .

  6. A CC machine for thermoplastics Viterbi School of Engineering .

  7. Nozzle Assemblies Viterbi School of Engineering .

  8. Plastic Parts Viterbi School of Engineering .

  9. Cylinder Connector Bevel gear Nozzle Side trowel mechanism of movable side trowel Movable Side Trowel Viterbi School of Engineering .

  10. Building Various Surface Slopes Viterbi School of Engineering .

  11. Slant Wall Fabrication Viterbi School of Engineering .

  12. Creating hollow depositions Viterbi School of Engineering .

  13. Embedding Reinforcement Viterbi School of Engineering .

  14. Application in Construction Viterbi School of Engineering .

  15. 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 .

  16. 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 .

  17. Non-farm productivity index Construction Productivity index Labor productivity comparison for non-farm industries and construction industry developed by Paul Teicholz Construction productivity decline Viterbi School of Engineering .

  18. Edison’s concrete houses $175,000 for molds More than 2000 pieces 500,000 pounds Viterbi School of Engineering .

  19. Concrete Surface Treatment Robot 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. Viterbi School of Engineering .

  20. Big-Canopy high-rise pre-cast concrete construction system. Used to construct the 26 storey pre-cast concrete 30,726m2 Yachiyodai Condominium building in Japan. The system realized a60% reduction in labor requirementsfor the frame erection. Viterbi School of Engineering .

  21. Form work cost structure Viterbi School of Engineering .

  22. A straight wall builder Viterbi School of Engineering .

  23. Full scale wall sections Viterbi School of Engineering .

  24. Viterbi School of Engineering .

  25. Viterbi School of Engineering .

  26. Adobestructures – Ageless comfort and beauty House of Brojerdi Kashan Viterbi School of Engineering .

  27. Interior of an Adobe house CalEarth Design Viterbi School of Engineering .

  28. House made with vaults and domes Interior of an Adobe house CalEarth Design Viterbi School of Engineering .

  29. Manual construction of adobe form structures using clay bricks (Source: Khalili, 2000) A vault structure made of clay bricks (Source: Khalili, 2000) Ingenious methods Viterbi School of Engineering .

  30. Free-standing Objects / Industrial parts Viterbi School of Engineering .

  31. Adobe house Construction Viterbi School of Engineering .

  32. Extraterrestrial Construction Viterbi School of Engineering .

  33. Deployable CC Viterbi School of Engineering .

  34. Lunar Construction Viterbi School of Engineering .

  35. Machine at NASA Viterbi School of Engineering .

  36. Viterbi School of Engineering .

  37. Viterbi School of Engineering .

  38. Viterbi School of Engineering .

  39. Next Machine Viterbi School of Engineering .

  40. Viterbi School of Engineering .

  41. Research specimens (concrete) Viterbi School of Engineering .

  42. Please visit www.ContourCrafting.org Viterbi School of Engineering .

  43. What constitutes construction cost? Viterbi School of Engineering .

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