Material and programme costs were supplied by VUW SoAD

Thesis

Master of Architecture

February 2019 HOW to Prefab

Freeform 3D Printing

PROJECT INTENTRobotic Arm printing modelFreeform 3D-printed wall - model

2018 Armano Papageorge’s Master of Architecture thesis delves into the never-ending possibilities of structural three-dimensional (3D) printing. Further studies intend to explore how concrete could be used to introduce this building typology into the construction industry as wall, floor and roof assemblies.

This case study focuses on Armano Papageorge’s Master of Architecture thesis. The motivation for this research was to explore innovative construction methodologies to establish freeform 3D-printing as a viable offsite construction method.

This research intends to address issues related to the New Zealand (NZ) housing crisis and construction waste. Conventional construction within NZ’s building industry still uses predominantly 200-year-old craft-based techniques. University-led Research and Development (R&D) has been utilised to explore innovative construction techniques that push the boundaries and offer the industry a new perspective.

Papageorge completed his thesis in 2018, and has since begun research at Doctorate level which he is aiming to finish in 2021.

A methodical and iterative trial-and-error approach was key to reaching the achieved level of resolution of this research. A series of iterative tests were conducted using technologies and programs at the Victoria University of Wellington (VUW) School of Architecture and Design (SoAD) campus.

Quantitative virtual prototyping and structural optimisation computer code were used as the primary testing method. Rhino (3D modelling software) was used to visualise forms and Grasshopper (a plug in for Rhino) was used to generate the code that dictated the 3D printing tool path. Millipede (an add on for Grasshopper) was used for the typology optimisation and finite element analysis options.

The primary objective of the code was to achieve a high level of mass customisability while reducing the structural material. The design also had to be fully customisable for different patterns and densities.

TESTING

3D Printed Plastic

Student: Armano Papageorge

Architecture and Sustainability

Victoria University of Wellington

Component / Open Panel

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Thesis completed in 2018

National Science Challenge 11 (NSC11) - “Building Better Homes, Towns and Cities”

Kevin Sweet + Tim Miller

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0m 6m 9m3m 12mCOST (NZD) TIME (months)

Freeform 3D Printing The second testing criteria related to the physical output. This ensured that the physical outputs resembled the digital models and the corresponding data. The final success criteria were that it needed to be printed with minimal human interaction, minimal material, and support a large amount of weight proportional to the structure’s own.

Algorithmic design, robotic technologies and 3D-printing have unlimited possibilities for sustainable design and construction. To extend this research to develop a viable construction method for NZ, Papageorge intends to work in collaboration with Callaghan Innovation to produce NZ’s first 3D-printer for concrete construction.

Papageorge believes that factory-based 3D-printing can completely eliminate uncertainties associated with conventional construction, and as a result can create a cost-efficient, healthy, and safe construction alternative.

Recyclable plastics were used with the structural optimisation code in an effort to reduce waste through re-use. The material used for testing was BigRep Pro High Temperature (PRO HT) plastic filament which is recyclable by a machine at VUW SoAD.

APPLICABILITY TO INDUSTRY

APPLICABILITY TO INDUSTRY

MATERIAL

HOW to Prefab Freeform 3D Printing - MArch Thesis

REFERENCES

Armano Papageorge. Personal Communication with Eleni Timoteo. January 2019. Images: Courtesy of Armano Papageorge

Freeform 3D-printed wall model

Freeform 3D-printed test model

Freeform 3D-printed test model

prefabnz.com

For more information on this project visit:https://issuu.com/armanopapageorge/docs/thesis_final

Papageorge envisions the developed typology will likely have high upfront costs as the algorithmic code (that encompasses all design variables) needs to be determined prior to the procurement and manufacturing process. These set-up costs are estimated to save clients money down the track through enabling them to know the digital design, the materials required, the total construction time, and the project cost immediately. This opposes conventional construction methods that tend to accumulate additional costs throughout the procurement and construction process.