3D PRINTING

APPLICATIONS IN CONSTRUCTION
3D PRINTING
● 3D printing or additive manufacturing is a computer-controlled production technique that
builds a product layer by layer.
● It is called additive manufacturing because a new material is continually added to it when it
wants.
● The 3D printing process builds a three-dimensional object from a computer-aided design (CAD)
model, usually by successively adding material layer by layer, which is why it is also called
additive manufacturing, unlike conventional machining, casting and forging processes, where
material is removed from a stock item (subtractive manufacturing) or poured into a mold and
shaped by means of dies, presses and hammers.
PROCESS
● MODELLING
3D printable models may be created with a computer-aided design (CAD) package, via a 3D scanner, or by a
plain digital camera and photogrammetry software. 3D printed models created with CAD result in reduced
errors and can be corrected before printing, allowing verification in the design of the object before it is
printed. The manual modeling process of preparing geometric data for 3D computer graphics is similar to
plastic arts such as sculpting.

● PRINTING
Before printing a 3D model from an STL file, it must first be examined for errors. Most CAD applications
produce errors in output STL files, of the following types:
holes;
faces normals;
self-intersections;
noise shells;
manifold errors.
Once completed, the STL file needs to be processed by a piece of software called a "slicer," which converts the
model into a series of thin layers and produces a G-code file containing instructions tailored to a specific type of 3D
printer (FDM printers). This G-code file can then be printed with 3D printing client software (which loads the G-
code, and uses it to instruct the 3D printer during the 3D printing process).

● FINISHING

Though the printer-produced resolution is sufficient for many applications, greater accuracy can be achieved
by printing a slightly oversized version of the desired object in standard resolution and then removing
material using a higher-resolution subtractive process.
3D PRINTERS
Main components of 3D printers:
● 3D Printer Frame: Holds the machine together
● 3D Printer Head movement mechanics: moves relative to the print bed in all directions
● 3D Printer Head: Nozzle that deposits filament or applies colors and liquid binder
● 3D Build Platform or Build Bed: The part of the printer where the object is printed
● 3D Printer Stepper Motors (at least 4): Used for precise positioning and speed control
● 3D Printer Electronics: Used to drive motors, heat the extruder and much more
● 3D Printer Firmware: Permanent software used to control every aspect of a 3D printer
● 3D Printer Software: Not part of the actual printer but still needed for the printing process
3D printer used for building constructions:
Buildings Built Using 3D Printer
DFAB House
Location: Dübendorf, Switzerland

Specifications: 200 square meters

Year of Construction: 2019

DFAB HOUSE is the world’s first inhabited house which was both digitally planned and built. Launched in February 2019, this project
was done by professors at ETH Zurich in cooperation with industrial partners, carried out with the help of robots and 3D printers. The
three-story structure lays on top of the NEST platform. Its goal is to test new construction and energy technologies under real-life
conditions. Ultimately, the aim is to make planning and construction with digital technologies more efficient and sustainable.
Gaia
Location: Italy

Specifications: 12-square-meters

Year of Construction: 2018

Architect: Alberto Chiusoli, WASP

Gaia accounts for the realization of WASP into a tangible house. This 3D printed model applies the Crane WASP technology, which uses
natural material from the surroundings. The eco-sustainable model employs raw soil and natural waste from the rice production chain,
aiming to achieve an efficient product from a bioclimatic perspective. it is a perfect approach to building low-cost houses. Additionally,
their design avoids the need for heating or air conditioning systems throughout the year.
New Story
Location: El Salvador

Specifications: 650-square-foot homes

Year of Construction: starting in 2017, ever-growing project.

Architect: ICON and New Story

New Story is a non-profit organization building affordable and secure houses for vulnerable communities. However, traditional
homebuilding is not sufficient for satisfying the need of shelter with a growing population. Thanks to its partnership with ICON, a
construction company based in Austin, Texas, the Vulcan 3D concrete printer could be the key to provide homes for those in “survival
mode”. Each structure takes around 120 to 240 hours to produce. Moreover, sustainable houses are expected to cost only $4,000.
Bicycle Bridge
Location: Netherlands

Specifications: 3.5 meters wide, 8 meters long

Year of construction: 2017

Architect: Technical University in Eindhoven & BAM

The Technical University in Eindhoven created a 3D printed bicycle bridge using reinforced and pre-stressed concrete. The bridge was
printed in eight individual parts. A concrete mortar was used to put the pieces together on site.

The final bridge measures 3.5 meters wide and 8 meters long and connects roads in the town of Gemert. Unlike traditional concrete
mixtures, the material utilized for this project has unique properties. Instead of running on all sides, this special concrete keeps its form
once it’s laid down. This means that there is less waste, which is extremely beneficial to the environment
Shamballa Village

Location: Massa Lombarda, North Italy

Specifications: several hundreds of square meters

Year of construction: 2016

Architect: Wasp

The village of Shamballa will be the first village completely created by a 3D printer. WASP set up one of its giant BigDelta 3D printers
to build one house after the other on-site. The 12-meter high BigDelta has to be moved to the next site once a 3D printed house is
finished. The 3D printed houses are made from mud or clay and plant fibers for reinforcement. Wasp decided to use material that is
locally available instead of concrete because of the low environmental footprint and because of the high insulating properties.
Surprisingly, building the first 3D printed house cost only 48 Euro.
ADVANTAGES
● Recycle concrete, building waste & industrial wastages are used in stood of using bricks & motor.
● Cheap in construction when compared to reinforced cement concrete.
● By using waste materials like concrete waste etc are recycled.
● The system extrudes a mix of high grade cement & glass fabric material, layer by layer, similar to traditional rapid prototyping
process gives more strength to this concrete.
● Less labor is required in this construction works.
● Durability of this concrete is very high.

● It is easy to construct a colony within a short period of time.

● This printer is easy to carry by folding it.

● It can fit windows, electrical lines & plumbing works etc.

DISADVANTAGES
● Reduced employee numbers in the industry, since the 3D printer does most of the work.
● A limited number of materials can be used, since the same printer might not be able to print the required
multiple materials.
● Higher risks – any errors in the digital model can result in problematic issues on site during the
printing/construction phase.
● Conventional product manufacturing companies and plant renting companies could suffer as their products
are no longer required
● By using this technology the structures will constructed quickly, cheaply, economically, recycles, reduction
of waste materials & eco friendly .The technology used to build colonies for people who are economically
poor with low capital. This technology will create a resolution in future in civil engineering projects.