Green-State Surface Finishing Techniques for 3D Printed Concrete, Mortar, and other Malleable Materials
Campaign: Digital Fabrication with Additive Manufacturing – Key for Innovation in Construction
Our project introduces an innovative automated surface finishing method for 3D-printed architectural elements. Addressing the challenge of post-production surface quality, which is often rough and uneven, we focus on processing and improving the surfaces of full-scale 3D printed structures, during the printing process.
Traditional manual finishing methods struggle with the complexity of 3D-printed surfaces. In the context of our research at the ETH Zurich, a prototypical mobile robotic setup applying plaster-based materials for surface finishing has been developed (currently in the state of incorporation as a spin-off, namely, LAYERƎD). In the context of the Innobooster Additive Manufacturing challenge, we aim to refine this technology for the finishing of 3D-printed building structures in their green state, focusing on single-material finishes. Our strategy involves a novel, ultra-thin layer plaster printing method using our mobile manipulator on construction sites to execute surface finishing, reducing the need for intensive manual labor.
Partnering with Holcim, we plan to refine digitally fabricated walls using materials like concrete, mortar, and earth-based materials. Holcim will provide access to their printing facilities, which is key to our technology’s development and testing.
With SUHNER AG, as the pioneers in robotic grinding, the goal is to integrate their advanced technology into our robotic system, leveraging their expertise in development and integration.
The proposed partnership will enable to address the overarching challenge – the “last cm” of building structures – with autonomous, high-quality surface finishing, directly on construction sites, in their green state.
With this association, our aim is to accelerate the exploration of novel surface finishing methods through the use of on-site mobile robotics, accelerating access to further pilot projects and contributing to the NCCR DFAB Phase III efforts to transfer the technology to the industry
