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3D printing in Construction: Application framework for a robotic arm based

on the extrusion technique

Conference Paper · March 2018

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 3D printing in Construction: application framework for a
robotic arm based on the extrusion technique
Zoubeir LAFHAJ 1*, Andry Zaid RABENANTOANDRO 1, Imane KRIMI1, Zakaria DAKHLI1,
Laure DUCOULOMBIER2, Thomas DANEL1, Emna ATTOURI1, Melanie DENECKER1
1
Department of Civil Engineering, Ecole Centrale de Lille, Lille, France
2
Bouygues Construction, Saint-Quentin-en-Yvelines, France
* Corresponding author (rabenantoandro.zaid@gmail.com)

Abstract – 3DCP (3D concrete printing) recently gained a
rapid development and showed a large range of potential
applications in construction. The latter may drastically
evolve thanks to the technique used in 3D printing, which
consists in an additive manufacturing process where
products are built on a layer-by-layer basis, through a series
of cross-sectional slices. This article examines the use of
industrial existing solutions to match the need for 3DCP
based on the extrusion technique in the construction
industry. The first part of the paper adapts an intermediate
route with existing technologies. After that, the coordination
of those technologies is set to develop an operational 3D
Printer. Based on this experimentation, we propose an
application framework for 3D printing in construction
based on the extrusion technique piloted by a robotic arm.
manufacture any desired geometry, which gives 3D printing
advantages over conventional techniques [3].
Process automation improved the efficiency of many
industrial segment in production. The construction industry,
however, is still way behind in this quest of efficiency [4]. The
adoption of automation, specifically the AM can bring
significant improvements in terms of safety, economic benefits,
and project completion on time and on budget [4]–[6].
Advanced automation has improved the efficiency of the
manufacturing sectors [7]–[9]. The construction industry, on the
other hand, has been skeptical to embrace new technologies,
such as automation. The last game changing technology was the
crane tower. Significant improvements could be gained from
introducing new technologies.

Keywords – 3D printing; Industrial Robot; Construction

industry; Additive manufacturing; Concrete, robotic arm
1 Introduction
3D printing (3DP) or “additive manufacturing (AM)”
experienced a rapid growth in the last two decades, it arouses
great expectation on many minds from researchers and
professionals to entrepreneurs and hobbyists [1]. 3D printing is
defined by the American Society for Testing and Material
(ASTM) as the process of joining materials in order to make a
whole object from a 3D model data [2].
The ASTM, in collaboration with the international Organisation
for Standardization (ISO), defines standard terminology for AM.
The document divides the AM technology into seven different
processes as detailed in the Table 1, Table 2, and Table 3.
The rapid evolution of this technology makes the classification
into categories difficult. A recent survey in 2016 [1] shows that
Selective Laser Sintering (SLS), Fused Deposit Modeling (FDM)
and Stereolithography (SLA) are the most used technologies in
the world. The control of materials enables the freedom to
3D printing takes an active part in the Fourth Industrial
Revolution. Through literature, we identified projects linked to
3D Printing in Construction such as (non-exhaustive list) :
Contour Crafting [10], 3D-P (MIT) in United State, Winsun in
china, D-Shape from Italy, CyBe Construction from the
Netherlands, Lund University from Sweden, Eindhoven
University of Technology from the Netherlands [8], XtreeE
from France and last but not the least in the region of “Haut de
France” Ecole Centrale de Lille [11].
The differentiating line between traditional manufacturing
methods and 3D printing methods is still not clear, thus it is
important to establish a framework to qualify components or
products that could be manufactured using 3D printing
techniques. This framework should also be dynamically updated
to be in sync with the latest developments in 3D printing
processes.
The challenge being made for 3D printing is the scale and
the complexity of geometry. Some works have already
demonstrated that complex geometries could be realized with
3DP at a desktop scale [8], The 3D printing process is based on
the FDM technique (the material is deposited layer by layer
through an extrusion printhead) [12].

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 Table 1: Type of technology used in 3D printing
Type of AM Material extrusion Power Bed Fusion
Specific name FDM (Fused Deposit MJF SLS SLM (Selective Laser Melting EBM
Modeling) (Multi (Selective (Electron
Jet Laser Beam
Fusion) Sintering) Melting)

Material Composite Plastic Plastic Plastic Metal Metal

Information - Fused Fused with Laser Fused with
with electron
agent Beam
and
energy
Companies Stratasys, Ultimaker, HP EOS, EOS, 3DSYSTEM, SLM, Conceptlaser Arcam AB
using these Printbot, Markforged 3DSYSTEM,
technologies (composite) SINTERIT,
Sintratec

Table 2: Type of technology used in 3D printing

Type of AM Vat Photopolymerization Material Jetting
Specific name SLA DLP (Digital CDLP Material Nanoparticle Drop On
(Stereolithography) Light (Continious Jetting (MJ) Jetting (NPJ) Demand
Processing) Digital Light (DOD)
Processing)
Material Plastic Plastic Plastic Plastic Metal Wax
Information cured with lazer Cured with Cured with
projector led and
oxygen

Companies 3DSYSTEM, Formlab, Envisiontec Carbon3D, Stratasys, XJET Solidscape

using these DWS Envisiontec 3Dsytem
technologies

Table 3: Type of technologies used in 3D printing

Type of AM Direct energy deposition Sheet lamination Binder jetting
Specific name Laser Electron Beam Laminated Object Manufacturing Binder Jetting (BJ)
Engeneering Additive (LOM)
Net Shape Manufacturing
(LENS) (EBAM)
Material Metal Metal Composite Paper Gypsum sand Metal
Information - - - - - -
Companies Optomec SCIAKY Inc Mcor, Impossible Object, Voxeljet, 3Dsystem, ExOne
using these envisiontec
technologies

formulation”. No criteria are yet set to limit the machinery nor

the concrete specifications. Thus, various effort must be made
to standardize the 3DPC technology in the construction industry.
2 Research objectives It is commonly accepted that the printing material should
respond to a certain number of specifications, to be considered
2.1 Goal of the current study printable, such as its workability, buildability, shape
There is no relevant guideline for the 3DCP in terms of stability[13]. No standardized method for evaluating printability
machinery specification or material formulation “concrete of construction materials (and specifically cementitious
200
materials) is developed and validated. The goal of the current
study is to present a framework for a robotic arm-based 3D
printer applied to construction and the evaluation of the
optimum characteristic of this printing process. It should be
noted that only the robot’s speed, printing quality, and fresh
properties (workability) of the printing mixture are considered
in this study. Further research is being conducted to investigate
the structural requirements for the hardened printing mixture.
The development of this kind of framework for laboratory
testing will contribute to establishing 3D printing guidelines for
the construction industry.
3 Experimental program.
3.1 Basics of the 3D printing process
The process of 3D printing is composed of 3 main steps [1]:
1. Create a virtual object using a CAD (computer-aided
design) technologies. this is the digital design information
needed to print an object. Digital models can be created
from scratch using design programs such as CAD or by
using a scanner to capture a 3D virtual image of an existing
object. 3D modelling software “slices” the model into
hundreds or thousands of horizontal layers, depending on
Figure 1: comparison between Plastic 3D printer and 3D Concrete Printer
201
the size and structure of the object to construct a physical
object out of the virtual model.
2. Choose the right Material. The object should be able to
withstand the stress and the external.
3. Choose the right 3D printer. The Choice of the hardware
is essential to create the solid object from the digital model.
The choice is linked to the material because of the
hardware specifications that come in various forms. Other
criteria for selection are linked to whether the application
is intended for public consumers or companies.
3.2 Plastic 3D printer vs 3D Concrete printer
Figure 1 presents a comparison between the printing process
of Plastic 3D printer and 3D Concrete printer. One main
difference is the trajectory, which is executed by a robotic arm
(for 3DCP) instead of the commonly used cartesian robot (for
Plastic 3D Printer). From the material standpoint, a pump is used
to bring and extrude the concrete to the head printer. The box
“3D Printer” in the figure constitutes the “hardware” and
consists of elements (type of robot, head printer, and extruder)
that are assembled together.
 manage the machinery. Figure 2 presents the proposed
framework for the robotic arm based on the extrusion technique.
3.3 The framework for a robotic arm based on the The framework was designed to be applicable to different 3D
extrusion technique Printing robotic arms in Construction.

The framework connects the material used for printing and

the 3D Printing machinery with the aim of determining the
optimum use of the material on hand and the proper process to

Figure 2: Proposed framework for a robotic arm intended for 3D Concrete printing

202
3.4 Concrete printing setup (machinery)
This section details the elements that compose the mentioned
framework.
3.4.1 Six axis industrial robot
An industrial robot is a manipulator designed to move materials,
parts, and tools, and to perform a variety of programmed tasks
in manufacturing and production settings. Industrial robots are
reshaping the manufacturing industry. They are often used to
perform duties that are dangerous or unsuitable for human
workers. The six axis robot is used to follow and simulate the
trajectory of the printing process [14].
3.4.2 Mixer and screw pump
Pumping concrete is a widely used method for distribution and
placement of concrete [15]. Concrete distribution is based on the
pumpability of materials which depends on different parameters
such as flow, placement of concrete and hardened properties. In
Figure 3: Complete experimental setup for 3DCP
4 Results and discussion
4.1 Optimal characteristics of the printing machine
 To find the optimum pump flow for the 3DCP based on
the proposed framework, cords are printed at different
flow rates. Each cord contains 4 segments.
 The speed is defined using an interval [a, b, c, d] that
contains 4 values. Each value corresponds to the print
speed value of a segment. Figure 4 shows the
trajectories with the different speed values for each
segment.
 The flow of the pump is controlled by a laboratory
power supply that gives an output voltage between 0 -
203
the proposed framework, we use a universal screw pump
suitable for mortar distribution. The speed and reversible paddle
rotation can ensure an optimized mixture even for difficult
products to batch such as semi-dry mixtures and thixotropic
products.
3.4.3 Printable material
A premix of Cementous material was developed with regard to
the constraint imposed by the pump, robot, and layer by layer
manufacturing process. The mixture is composed of cement (35 %
of total Weight), fine aggregate (Ø ≤ 4 mm), and an admixture.
3.4.4 Complete experimental setup “printing machine”
Figure 3 presents the complete experimental setup of the
construction printing process. The different components are
linked together, to coordinate the task in hand an autonomous
controller enslaved the pump and Robot for control and
programming.
10 V. For a given voltage, the flow is constant
depending on the material characteristics. The flow is
then fixed using a constant voltage for cords test and
linked to the best printing quality obtained.
 From the pump control system standpoint, a lower
input voltage means a low flow output.
Figure 4: Robot trajectory for calibration of optimal
characteristic
Table 4 presents a synthesis of each proposed test on the first
cords printing tests. Error! Reference source not found.
illustrates the texture and quality of the first cords printing tests.
The pump is not used at its optimum, and therefore it induces
unsteady flow and a sinus printed cord as we can see in Figure
5.
 Figure 4: Robot trajectory for calibration of optimal characteristic

Table 4 : Speed of robot and input voltage for pump flow

Speed of robot (cm/s) Pump voltage(V)
[a, b, c, d]
Test 1 [5, 6, 7, 8] 1.5
Test 2 [5, 6, 7, 8] 2.5
Test 3 [5, 6, 7, 8 ] 3
Test 4 [8, 9, 10, 11] 3
Test 5 [8, 9, 10, 11] 3.5
Test 6 [12, 13, 14, 15] 3

Figure 5: Different cords for test of printing

204
4.2 Printing tests for flow and printability corner but soft in the upper face as illustrated in Figure 9. The
printed material does not present any cracks at the base (first
The first printing test was to print the acronym “CC4.0” in order layer). Due to the anisotropic nature of FDM printing, the
to test circular and linear trajectories, with five layers of 10 mm- printed materials are weaker in one direction (effect of the
height each. Table 5 highlights the difference between the layer’s orientation). The superposition of materials layer by
robot’s speed and the flow of the pump. layer with a rectangular form and rounded ends creates stress
concentration and eases the formation of cracks. The material’s
Table 5: Speed of robot and input voltage of the screw pump behaviour at early and mature ages influence the superposition
Speed of robot and input voltage on pump process and the overall properties of the final object [14].
Test Interval Pump
Speed voltage
(cm/s) (V)
Test 1 12 3
Test 2 4-1 1.8 - 2.05
Test 3 8-6 1.8 - 2.05

Figure 9: Height and superposition of the printed layers

Figure 6: Printing test 1
Figure 7: Printing test 2
5 Conclusion
Additive manufacturing offers new production opportunities
such as the manufacturing of highly customized modules. For
the construction industry, 3D printing is highly dependent on the
control of every entities that constitute the printing system. In
this article, we proposed an application framework for a robotic
arm based on the extrusion technique. This framework connects
the material used for printing and the 3D Printing machinery
with the aim of determining the optimum use of the material on
hand and the proper process to manage the machinery.
The second part of the paper determines, based on
experimental tests, the optimal set characteristics of the printer.
The latter is 8 cm/s in speed of printing and a pump voltage of 2
V. Limitation on the printability window of Cementous material
and poor control on flow of the pump are areas of optimization
in future research studies.

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