Abstract
We present research work on a manufacturing process deploying natural composite materials. The objective of the project is to create a sustainable manufacturing process integrating materials, hardware, software and fabrication logic from the ground up. We deploy a bioinspired natural composite comprised by renewable, widely available, biodegradable and low-cost natural components. Material properties closely resemble those of high-density foams or low-density timbers and it is produced without any petrochemical or harmful solvents associated with adverse environmental effects. We designed a mobile material deposition system using the Direct Ink Writing method, with work envelope of over 3 m vertically and indefinite horizontal range, comprised of industrial robotic hardware and purpose-built mechanical mobile platform. We performed testing in characterizing material properties with and without the introduction of the printing process, tightly integrated material behavior with manufacturing and developed design software for direct transition from design to production. To address scaling, we approached the fabrication process from the perspective of fusing the best principles from both additive and subtractive manufacturing, offering geometric freedom and material efficiency of additive manufacturing while targeting production and quality efficiencies of subtractive and forming processes. We believe this process has the potential of significant impact on general manufacturing as well as the building industry.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
3D Systems Inc.: 3D Printing Materials. https://www.3dsystems.com/materials/. Accessed 10 Feb 2018
Materialise: Materials http://www.materialise.com/en/manufacturing/materials/. Accessed 10 Feb 2016
Martin, O., Averous, L.: Poly(lactic acid): plasticization and properties of biodegradable multiphase systems. Polymer 42, 6209–6219 (2001)
Bard, J., Mankouche, S., Schulte, M.: Morphaux, recovering architectural plaster by developing custom robotic tools. In: Brell-Çokcan, S., Braumann, J. (eds.) ROB|ARCH 2012: Robotic Fabrication in Architecture, Art and Design, pp. 138–141. Springer, Vienna (2013)
Friedman, J., Kim, H., Mesa, O.: Experiments in additive clay depositions. In: McGee, W., Ponce de Leon, M. (eds.) Robotic Fabrication in Architecture, Art and Design 2014, pp. 261–271. Springer International Publishing Switzerland (2014)
Dunn, K., Wozniak O’Connor, D., Nemela, M., Ulacco, G.: Free form clay deposition in custom generated molds, producing sustainable fabrication processes. In: Reinhardt, D., Saunders, R., Burry, J. (eds.) Robotic Fabrication Architecture, Art and Design 2016, pp. 317–325. Springer International Publishing Switzerland (2016)
Gramazio, F., Kohler, M.: Procedural Landscapes, Architecture and Digital Fabrication. http://www.dfab.arch.ethz.ch/web/d/lehre/211.html. Accessed 10 Feb 2018
Gardiner, B.J., Janssen, R.S.: FreeFab development of a construction-scale robotic formwork 3D printer. In: McGee, W., Ponce de Leon, M. (eds.) Robotic Fabrication in Architecture, Art and Design 2014, pp. 131–144. Springer International Publishing Switzerland (2014)
Fernandez, G.J., Mills, A.C., Samitier, J.: Complex micro-structured 3D surfaces using Chitosan Biopolymer. Small 5(5), 614–620 (2009)
Fernandez, J.G., Ingber, D.E.: Manufacturing of large-scale objects using biodegradable chitosan bioplastic. Macromol. Mater. Eng. 299(8), 932–938 (2014)
Lu, Z.J., Wu, Q., McNabb Jr., S.H.: Chemical coupling in wood fiber and polymer composites: a review of coupling agents and treatments. Wood Fiber Sci. 32–1, 88–104 (2000)
3D Systems Inc.: Tree-D Printing in Wood: https://www.3dsystems.com/blog/foc/freedom-of-creation-develops-tree-d-printing. Accessed 12 Nov 2016
Franke, R., Roffael, E.: Recycling of particle and fiberboards (MDF). Holz Roh Werkst. 56(1), 79–82 (1998)
Lei, H., Pizzi, A., Navarette, P., Rigolet, S., Redl, S., Wagner, A.: Gluten protein adhesives for wood panels. J. Adhes. Sci. Technol. 24, 1583–1596 (2010)
Pizzi, A.: Recent developments in eco-efficient bio-based adhesives for wood bonding: opportunities and issues. J. Adhesion Sci. Technol. 8, 829–846 (2006)
Lam, C.X.F., Mo, X.M., Teoh, S.H., Hutmacher, D.W.: Scaffold development using 3D printing with a starch-based polymer. Mater. Sci. Eng. 20, 49–56 (2002)
Tan, R., Sia, C.K., Tee, Y.K., Koh, K., Dritsas, S.: Developing composite wood for 3D-printing. In: Janssen, P., Loh, P., Raonic, A., Schnabel, M.A. (eds.) CAADRIA 2017: Protocols, Flows and Glitches, Proceedings of the 22nd International Conference of the Association for Computer-Aided Architectural Design Research in Asia, pp. 831–840. Suzhou (2017)
Mogas-Soldevilla, L., Duro-Royo, J., Oxman, N.: Water-based fabrication. 3D Printing Add. Manuf. 1, 141–151 (2014)
Stuecker, N.J., Miller, E.J., Ferrizz, E.R., Mudd, E.J., Cesarano, J.: Advanced support structures for enhanced catalytic activity. Ind. Eng. Chem. Res. 43(1), 51–55 (2004)
Lewis, A.J.: Direct ink writing of 3D functional materials. Adv. Funct. Mater. 16, 2193–2204 (2006)
Dritsas, S.: An advanced parametric modelling library for architectural and engineering design. In: Chien, S.F., Choo, S., Schnabel, M.A., Roudavski, S. (eds.) CAADRIA 2016: Living Systems and Micro-Utopias: Towards Continuous Designing, Proceedings of the 21st International Conference of the Association for Computer-Aided Architectural Design Research in Asia, pp. 611–620. Melbourne (2016)
Vijay, Y., Sanandiya, N., Dritsas, S., Fernandez, G.J.: Control process settings for large-scale additive manufacturing with natural composites. In: Proceedings of ASME (2018). in press
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2019 Springer Nature Switzerland AG
About this paper
Cite this paper
Dritsas, S., Vijay, Y., Dimopoulou, M., Sanadiya, N., Fernandez, J.G. (2019). An Additive and Subtractive Process for Manufacturing with Natural Composites. In: Willmann, J., Block, P., Hutter, M., Byrne, K., Schork, T. (eds) Robotic Fabrication in Architecture, Art and Design 2018. ROBARCH 2018. Springer, Cham. https://doi.org/10.1007/978-3-319-92294-2_14
Download citation
DOI: https://doi.org/10.1007/978-3-319-92294-2_14
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-319-92293-5
Online ISBN: 978-3-319-92294-2
eBook Packages: Intelligent Technologies and RoboticsIntelligent Technologies and Robotics (R0)