Firm foundations with 3D concrete printing

The MTC works in collaboration with Skanska, Foster + Partners, Tarmac, ABB, and Loughborough University to develop a 3D concrete printing system for industrial applications.

The Challenge

• The consortium behind the project were looking to further develop and industrialise the 3D concrete printing (3DCP) system, originally developed by Loughborough University.
• It would increase the scope of pre-cast 3D concrete printing with the aim to become the world’s first high-value commercial 3DCP system, that would be portable, offer endless variability, increase productivity, reduce lead times and waste compared to current casting methods.

MTC's solution

• The system was moved to the MTC in early 2016 and redesigned for safe handling of materials and robot operation.
• The deposition head was upgraded to improve control and cleaning.
• Improved setup and clean down processes to enhance ease of use.
• Improved material knowledge and understanding of the effects of each ingredient within the 3DCP material recipe with the assistance of Tarmac.
• Repeatability testing of prints designed by Foster + Partners to ensure robustness of the system

The Outcome

• The ability to resolve material issues and highlight areas for future improvement activities.
• Normalisation of process, improving repeatability and consistency of prints.
• Development of the concrete dispenser resulting in the reduction in footprint, mass and cost.
• Tooling design improvements allowing for more complex shapes to be printed.
• Development of future 3DCP system shifting from batch process to continuous process for increased flexibility.

Benefits to the client

• Improvement in print design complexity with improvements in flexibility, repeatability and consistency.
• Elimination of manual handling activities.
• Improved safety and reduced complexity for 3DCP operators.
• Increased productivity, with reduced lead time and process downtime.
• Reduced production of waste.