| id |
acadia20_202p |
| authors |
Battaglia, Christopher A.; Verian, Kho; Miller, Martin F. |
| year |
2020 |
| title |
DE:Stress Pavilion |
| source |
ACADIA 2020: Distributed Proximities / Volume II: Projects [Proceedings of the 40th Annual Conference of the Association of Computer Aided Design in Architecture (ACADIA) ISBN 978-0-578-95253-6]. Online and Global. 24-30 October 2020. edited by M. Yablonina, A. Marcus, S. Doyle, M. del Campo, V. Ago, B. Slocum. 202-207 |
| summary |
Print-Cast Concrete investigates concrete 3D printing utilizing robotically fabricated recyclable green sand molds for the fabrication of thin shell architecture. The presented process expedites the production of doubly curved concrete geometries by replacing traditional formwork casting or horizontal corbeling with spatial concrete arching by developing a three-dimensional extrusion path for deposition. Creating robust non-zero Gaussian curvature in concrete, this method increases fabrication speed for mass customized elements eliminating two-part mold casting by combining robotic 3D printing and extrusion casting. Through the casting component of this method, concrete 3D prints have greater resolution along the edge condition resulting in tighter assembly tolerances between multiple aggregated components. Print-Cast Concrete was developed to produce a full-scale architectural installation commissioned for Exhibit Columbus 2019. The concrete 3D printed compression shell spanned 12 meters in length, 5 meters in width, and 3 meters in height and consisted of 110 bespoke panels ranging in weight of 45 kg to 160 kg per panel. Geometrical constraints were determined by the bounding box of compressed sand mold blanks and tooling parameters of both CNC milling and concrete extrusion. Using this construction method, the project was able to be assembled and disassembled within the timeframe of the temporary outdoor exhibit, produce <1% of waste mortar material in fabrication, and utilize 60% less material to construct than cast-in-place construction. Using the sand mold to contain geometric edge conditions, the Print-Cast technique allows for precise aggregation tolerances. To increase the pavilions resistance to shear forces, interlocking nesting geometries are integrated into each edge condition of the panels with .785 radians of the undercut. Over extruding strategically during the printing process casts the undulating surface with accuracy. When nested together, the edge condition informs both the construction logic of the panel’s placement and orientation for the concrete panelized shell. |
| series |
ACADIA |
| type |
project |
| email |
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| full text |
 file.pdf (13,450,606 bytes) |
| references |
Content-type: text/plain
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Ballard, G., N. Harper, T. Zabelle (2019)
 Learning to see work flow: an application of lean concepts to precast concrete construction
, Engineering, Construction and Architectural Management, Vol. 10 (1): 6-14.
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Optimization in Green Sand Casting Process For Efficient, Economic, Economical and Quality Casting
, International Journal of Advanced Engineering Technology. Vol. V (1): 25-29
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Battaglia, C., M. Miller, S. Zivkovic (2019)
Sub-Additive 3D Printing of Optimized Double Curved Concrete Lattice Structures
, Robotic Fabrication In Architecture, Art, And Design 2018, Vol. 1, ed. J. Willmann, P. Block, M. Hutter, K. Byrne, T. Schork, 245-255. Heidelberg: Springer
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Additive Manufacturing of concrete in construction: potentials and challenges of 3D concrete printing
, Virtual and Physical Prototyping 11(3): 209-225
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Verian, K. P., S.R. Kowaleski, M.D. Carli, R.P. Bright, E. Maandi, and G. Still (2020)
The Properties of 3D Printing Mortar and Development of 3D Construction Printing
, Transportation Research Record, vol. 2674 (2): 1-9
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Zivkovic, S., C. Battaglia (2018)
Rough Pass Extrusion Tooling, CNC Post Processing of 3D-Printed Sub-additive Concrete Lattice Structures
, ACADIA 2018 Recalibration: On Imprecision and Infidelity: Proceedings of the 38th Annual Conference of ACADIA, ed. by P. Anzaline, M. del Signore and A.J. W, 302-311. Mexico City: ACADIA.
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| last changed |
2021/10/26 08:08 |
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