BIM, 3D Printing, Structures & the Future of Building Design
Introduction
The development of 3D Printing, or additive manufacturing is a process by which layers of material are stacked to form a 3D object, based on electronic data points. This contrasts the more typical machining methods of grinding or cutting, and allows for more delicate and unique shapes to be formed. 3D printing is often used in product design, or to make small architectural models as a method of rapid prototyping. Currently, it is a slow method for fabrication of larger projects, but some companies are experimenting with the technology.
Construction Applications
Skidmore, Owings & Merrill have demonstrated some success in using 3D printing to develop a green 450-square-foot carbon- fiber-reinforced ABS plastic structure. A benefit of a 3D printing method is the efficient use of material--there is much less scrap than in traditional construction. The printed material was a series of identical C shaped channels, with a grain like that of wood. Post tensioning tendons were incorporated in design to account for lower strength in the grain direction. [1] Interior materials and insulation were produced in a traditional way.
Arup developed a unique shape for street lights in the Hague. Their construction consisted of 1,200 steel pieces, few of which would be identical. Additive manufacture of metals involves using metal alloys in powder form, which are heated with lasers. Unused powder can be collected and reused. The number of unique pieces is difficult and expensive for manufacture, so 3D printing was used. The resulting pieces were some 50% lighter than they might have been if they were produced with traditional machining. [2]
Chinese construction company WinSun constructed a five story 3D printed apartment building. The primary material was a recycled mix of ground construction and industrial waste, around a base of quick-drying cement. The walls were backed with appropriate insulation, and steel members. WinSun estimates this process decreases construction waste by 30-60 percent, and labor costs by 50 percent. [3]
Benefits of 3D Printing
The benefit of 3D printing is that it can produce very complex shapes with great precision. This will make it easier to realize architecturally complex projects including those with organic, curved forms. Printing will likely be most seen in custom building elements, modular elements, or those with great variation in form. Facades are a likely target for additive manufacture. Additive manufacture is also environmentally friendly in terms of material use--there is very little or no scrap material, as only what is needed is custom made. 3D Printing can be used to develop cheap disaster housing, easily replicated, and produced around the clock.
Limitations of 3D Printing
Still, the technology to print a complete building system is still some years away. Printing structural elements is what there has been most development in, both as accessory components, and larger members. We do not yet have the technology to print insulation, glazing, piping, ductwork, or electrical equipment. Even once we have the technology to print these elements, we will have to test them extensively to ensure they meet the same technical requirements our traditionally manufactured materials do. Even if all of these materials are printed successfully, there will still have to be a great deal of assembly on site.
Resources
[1] http://www.architecturalrecord.com/articles/11652--d-printing
[2] http://www.asce.org/magazine/20140624-engineers-testing-3-d-printing-of-steel/
[3] https://www.cnet.com/news/worlds-first-3d-printed-apartment-building-constructed-in-china/
