usc viterbi school of engineering. mega-scale fabrication by contour crafting mega-scale fabrication...

43
Viterbi School of Engineering . USC Mega-Scale Fabrication Mega-Scale Fabrication by by Contour Crafting Contour Crafting Behrokh Khoshnevis University of Southern California

Upload: marilyn-alexander

Post on 29-Dec-2015

227 views

Category:

Documents


1 download

TRANSCRIPT

Viterbi School of Engineering .

USC

Mega-Scale FabricationMega-Scale Fabrication byby Contour CraftingContour Crafting

Behrokh KhoshnevisUniversity 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

Nozzle

Side trowel

Side trowel control mechanism

Top trowel

CC is a layered fabrication method which combines ancient surface forming concepts with modern robotics technology

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

Labor productivity comparison for non-farm industries and construction industry developed by Paul Teicholz

Construction Productivity index

Non-farm productivity index

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

Concrete Surface Treatment Robot

This robot absorbs the water which remains after concrete has been set.

Viterbi School of Engineering .

USC

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 a 60% reduction in labor requirements for the frame erection.

Viterbi School of Engineering .

USC

Form work cost structure

Ties

Wales

Studs

Sheathing

Concrete footing

Brace

Reinforcement

53%30%

10% 7% Formwork Labor

Concrete Materials

Formwork Materials

Concrete Labor

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 CalEarth Design

Viterbi School of Engineering .

USC

House made with vaults and domes

Interior of an Adobe house CalEarth 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.ContourCrafting.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