Concrete Additive Manufacturing System Design for Earth and Mars
Open Access
- Author:
- Watson, Nate
- Graduate Program:
- Additive Manufacturing and Design
- Degree:
- Master of Science
- Document Type:
- Master Thesis
- Date of Defense:
- July 07, 2020
- Committee Members:
- Sven G Bilen, Thesis Advisor/Co-Advisor
Nicholas Alexander Meisel, Thesis Advisor/Co-Advisor
Timothy W. Simpson, Program Head/Chair - Keywords:
- Additive Manufacturing
3D Printing
concrete
additive construction
robot
mars - Abstract:
- This work explores additive manufacturing of concrete using a six-axis robotic arm and its use in large scale, autonomous concrete construction. Concrete additive manufacturing uses an extrusion method to deposit concrete beads in layers to create a three-dimensional shape. This method of construction has been found to have many uses and advantages in both terrestrial and extraterrestrial applications. The lack of formwork and the autonomous nature of this manufacturing method allows for new geometries and materials to be printed where it may not be safe for humans to go. Autonomous construction has been suggested as a method of creating habitats for humans on Mars and on the moon using in-situ materials. This thesis presents research towards systems that could be used on the surface of Mars as well as on Earth, which required increasing the capabilities of a six-axis robotic arm along with overcoming system challenges to achieve deliverables for the NASA’s “3D Printed Habitat Challenge”. The system designed increased the build volume, integrated embedding, printed non-coplanar sections, and addressed issues with continuous extrusion and implications of toolpaths that minimized travel moves. The system was demonstrated by printing a one-third-scale Martian habitat for which the team printed the first fully enclosed structure at an architectural scale without the use of support.