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Automated Construction by Contour Crafting Berok Khoshnevis University of Southern California

Automated Construction by Contour Crafting Berok Khoshnevis University of Southern California. Fabrication Processes. Subtractive (milling, turning, chiseling, sawing,..) Formative (pressing, forging, bending,..) Additive Casting (requiring mold)

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Automated Construction by Contour Crafting Berok Khoshnevis University of Southern California

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  1. Automated ConstructionbyContour CraftingBerok 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. 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 .

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

  6. Nozzle Assemblies Viterbi School of Engineering .

  7. Plastic Parts Viterbi School of Engineering .

  8. CC Machine for Ceramics Viterbi School of Engineering .

  9. Viterbi School of Engineering .

  10. Comparison of the flow pattern with the simulation result and the actual process on the near optimal conditions: side views with a square orifice (top pictures), and side views with an elliptical orifice (bottom pictures) Process & Machine Design Research Viterbi School of Engineering .

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

  12. Building Various Surface Slopes Viterbi School of Engineering .

  13. 2.5D and 3D Objects Viterbi School of Engineering .

  14. Application in Construction Viterbi School of Engineering .

  15. 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 .

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

  17. Construction by Contour CraftingCCC Viterbi School of Engineering .

  18. Cavities made with CC and filled with concrete Viterbi School of Engineering .

  19. Embedding Reinforcement Viterbi School of Engineering .

  20. A straight wall builder Viterbi School of Engineering .

  21. Viterbi School of Engineering .

  22. Viterbi School of Engineering .

  23. Viterbi School of Engineering .

  24. Conventional Structure Construction Viterbi School of Engineering .

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

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

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

  28. 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 .

  29. Supportless structures created by CC Viterbi School of Engineering .

  30. Adobe house Construction Viterbi School of Engineering .

  31. CRAFT Center for Rapid Automated Fabrication Technologies • University of Southern California • Massachusetts Institute of Technology • Purdue University • California State University, Los Angeles Viterbi School of Engineering .

  32. Grand Challenge • The grand challenge for CRAFT is building a custom-designed house in a day while radically reducing the costs, injuries, waste and environmental impact associated with traditional construction techniques. The goal is a revolution in housing construction, whether it be to provide: • affordable housing for the 30 million U.S. households facing cost burdens or overcrowding; • emergency housing for victims of natural (and/or man-made) disasters; • extraterrestrial buildings constructed from in situ materials; • new styles of housing based on curved rather than straight surfaces; or • inexpensive first ownership housing for an emerging middle class in the developing world • With national construction-related expenditures currently totaling close to $1 trillion annually, the potential impact is enormous. Viterbi School of Engineering .

  33. Vision and Goals More broadly the vision is to develop the science and engineering needed for rapid automated fabrication of structures of various scales, up to large objects such as buildings. To achieve this, CRAFT will develop a unique academic environment blending fundamental research with the development of large-scale engineered systems; engineering with computer science and architecture, and environmental, regulatory, labor and economic expertise; partnerships with industry; and educational and outreach programs. Viterbi School of Engineering .

  34. Technology Demonstrations – Mega-Scale Layered Fabrication – Industrial Parts & Molds Extraterrestrial Construction Freestanding Objects Architectural Scale Models Grand Challenge A House in a Day Public Art Economic Impact Social Impact Environmental Impact Regulatory Impact Architectural Impact Employment Impact Technology Thrusts Extrudable Materials and Fabrication Modular Components and Assembly Integrated Software Systems Fundamental Research Materials/Structures Sensing/Acting Systems/Processes Freeform/Geometry Composite Materials Dynamic Modeling and Control Workflow & Logistics Planning Mathematical Models of Fabrication Processes Fluid Dynamics Embedding Capabilities during Fabrication Multi-Robot Coordination Feasible Geometry Reasoning Novel Structure Testing Real-Time Inspection Collaborative Design 4D Modeling and Visualization System Performance Testing and Evaluation Viterbi School of Engineering .

  35. Economic Impact Employment Impact Social Impact Regulatory Impact Environmental Impact Architectural Impact Grand Challenge – a house in a day Viterbi School of Engineering .

  36. Development Phases Viterbi School of Engineering .

  37. Technology Demonstrations – Mega-Scale Layered Fabrication – Industrial Parts & Molds Extraterrestrial Construction Freestanding Objects Architectural Scale Models Grand Challenge A House in a Day Public Art Economic Impact Social Impact Environmental Impact Regulatory Impact Architectural Impact Employment Impact Technology Thrusts Extrudable Materials and Fabrication Modular Components and Assembly Integrated Software Systems Fundamental Research Materials/Structures Sensing/Acting Systems/Processes Freeform/Geometry Composite Materials Dynamic Modeling and Control Workflow & Logistics Planning Mathematical Models of Fabrication Processes Fluid Dynamics Embedding Capabilities during Fabrication Multi-Robot Coordination Feasible Geometry Reasoning Novel Structure Testing Real-Time Inspection Collaborative Design 4D Modeling and Visualization System Performance Testing and Evaluation Viterbi School of Engineering .

  38. Extraterrestrial Construction Viterbi School of Engineering .

  39. Deployable CC Viterbi School of Engineering .

  40. Lunar Construction Viterbi School of Engineering .

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

  42. Architectural Design Logistics plan Robot Integrated Modular Commands Nozzle path plan CC Software Components Hardware Assembly plans Systems Hardware & Assembly Inspection plan Feedback Visual Data Sensory Data Supply Dispatch Indexed Video Log Performance Restrictions Extrudable Structure design & Materials & Predictive Performance performance Requirements Fabrication Interrelationships among the three research thrusts Viterbi School of Engineering .

  43. Extrudable materials & fabrication • Perform underlying basic research necessary to develop the materials and structures for automated mega-scale fabrication • Integrate materials into ultra-efficient structures • Integrate materials with delivery systems and robots from other thrusts Viterbi School of Engineering .

  44. Co-extrusion of outer and filler materials A 6DOF Nozzle Assembly Viterbi School of Engineering .

  45. Viterbi School of Engineering .

  46. Robotics fab, modular components & assembly • Perform research and develop various mono and distributed robots, tools, software and their integration into systems for assembling modules in situ to form functional attributes of structures • Robots’ locations, movements and working areas are dynamically changing along with environment. Develop a mathematical / geometric model of environment and a robot coordination protocol. • Perform the fundamental research in the modules to be placed internal to the extruded material that transform an extrusion into a functional wall or roof of a mega-scale structure. The modules that make a post-modern interactive structure include: • normal reinforcing, plumbing, and electricity conduits • Integrated communication, interactive sensing and displays • Integrate the Modules and Assembly Thrust with Extruded Materials and Software Viterbi School of Engineering .

  47. Viterbi School of Engineering .

  48. Automated Painting Viterbi School of Engineering .

  49. FlowSensor Desired Material Flow - Flow Control Law Material Flow Computation Material Flow Dynamics + Material Flow System Dynamics Position Sensor Gantry Dynamic Model - Nozzle Forces Commanded Position Nozzle Position & Orientation Nozzle Control Law Nozzle Actuator + Wheel Torques Gantry Position Gantry Motion Controller Robot Wheel Motors Position Sensors Dynamic Control Viterbi School of Engineering .

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