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Construction by Contour Crafting
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Maslow’s Hierarchy of Needs
Self Actualization Needs (full potential)
Ego Needs (self respect, personal worth, autonomy)
Social Needs (love, friendship, comradeship)
Security Needs (protection from danger)
Physiological Needs (food, shelter)
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Why automate construction?
•
Labor efficiency is alarmingly low
•
Skilled workforce is vanishing
•
Work quality is low
•
Control of the construction site is insufficient and difficult
•
Accident rate at construction sites is high
•
Waste and trims are high (3 To 7 tons per average home; 40% of all materials used
(> 400,000 / year in US)
worldwide are for construction)
•
Low income housing and emergency shelters are critical
•
Construction is the largest sector of almost all economies
•
All other products are fabricated automatically – construction is still
largely a manual task
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Construction productivity decline
Non-farm productivity index
Construction
Productivity index
Labor productivity comparison for non-farm industries and construction industry
developed by Paul Teicholz
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Edison’s concrete houses
$175,000 for molds
More than 2000 pieces
500,000 pounds
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Automated construction in Japan
• 89 single task construction robots
• 11 different automated construction systems
This robot
absorbs
the water
which
remains
after
concrete
has been
set.
Concrete Surface Treatment Robot
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Big-Canopy high-rise pre-cast concrete construction system.
Used to construct the 26 storey pre-cast concrete 30,726m2
Yachiyodai Condominium building in Japan.
The system realized a 60% reduction in labor requirements for the frame erection.
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Form work cost structure
Reinforcement
Wales
Ties
Studs
Sheathing
Brace
Concrete footing
10%
7%
Formwork Labor
Concrete Materials
53%
30%
Formwork Materials
Concrete Labor
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ICF Homes – Reducing from work cost
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Concrete filling
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Insulation
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Construction by Contour Crafting
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What constitutes construction cost?
Portion
Due to
If Automated by CC
20%-25%
Financing
Short project length and control of
time to market will dramatically
reduce this cost
25%-30%
Materials
Will be a wasteless (lean) process
45%-55%
Labor
Will be significantly reduced
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Cavities made with CC and filled with concrete
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Creating hollow depositions
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Embedding Reinforcement
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A straight wall builder
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Full scale wall sections
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Conventional and CC forms
Sheathing
Tie washer
Studs
Concrete
form
Wales
Form tie
Tie rod
Tie nut
Cone Spreader
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Conventional Structure Construction
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Roof construction
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Adobe structures – Ageless comfort and beauty
House of
Brojerdi
Kashan
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Interior of an
Adobe house
CalEarth Design
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House made with vaults and domes
Interior of an
Adobe house
CalEarth Design
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Ingenious methods
Manual construction of adobe form structures
using clay bricks (Source: Khalili, 2000)
A vault structure made of clay bricks
(Source: Khalili, 2000)
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Free-standing Objects / Industrial parts
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Supportless structures created by
CC
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Adobe house Construction
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Extraterrestrial Construction
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Deployable CC
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Lunar Construction
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Road construction
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CC Machine at NASA Marshall Space Flight Center
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Lunar containers built at NASA
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The next machine
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Research specimens (concrete)
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CRAFT
Center for Rapid Automated Fabrication Technologies
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Technology Demonstrations
Industrial Parts
& Molds
Extraterrestrial
Construction
– Mega-Scale Layered Fabrication –
Architectural
Scale Models
Freestanding Objects
Public Art
A House in a Day
Economic Impact
Social Impact
Environmental Impact
Regulatory Impact
Grand Challenge
Architectural Impact
Extrudable Materials
and Fabrication
Modular Components
and Assembly
Employment Impact
Integrated Software
Systems
Technology Thrusts
Materials/Structures
Composite Materials
Fluid Dynamics
Novel Structure Testing
Sensing/Acting
Systems/Processes
Freeform/Geometry
Dynamic Modeling
and Control
Embedding Capabilities
during Fabrication
Workflow & Logistics
Planning
Multi-Robot
Coordination
Real-Time Inspection
Collaborative Design
Mathematical Models
of Fabrication Processes
Feasible Geometry
Reasoning
4D Modeling
and Visualization
System Performance
Testing and Evaluation
Fundamental Research
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Grand Challenge
Building a custom-designed house in a day while radically reducing the costs,
injuries, waste and environmental impact associated with traditional construction
techniques.
affordable housing for the 30 million U.S. households facing cost burdens or
overcrowding;
emergency housing for the 37 million/year victims of natural (and/or manmade) disasters;
new styles of housing based on curved rather than straight surfaces;
extraterrestrial buildings constructed from in situ materials;
With national construction-related expenditures currently totaling close to $1
trillion annually, the potential impact is enormous.
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Grand Challenge – a house in a day
Economic Impact
Employment Impact
Social Impact
Regulatory Impact
Environmental Impact
Architectural Impact
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Please visit www.ContourCrafting.org
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