Title: Automated%20Construction%20by%20Contour%20Crafting%20Berok%20Khoshnevis%20University%20of%20Southern%20California
1Automated Construction by Contour
CraftingBerok KhoshnevisUniversity of Southern
California
2Fabrication Processes
- Subtractive (milling, turning, chiseling,
sawing,..) - Formative (pressing, forging, bending,..)
- Additive
- Casting (requiring mold)
- Traditional Layered Fabrication in manual
construction - Modern Layered Fabrication (SFF or RP)
Technologies
3Commercialized RP Technologies
4 SIS Selective Inhibition Sintering
5(No Transcript)
6What is Contour Crafting?
CC is a layered fabrication method which combines
ancient surface forming concepts with modern
robotics technology
7A Scalable Process Ideal for Large Objects
Layer Height Several Centimeters Surface
Quality About 2 microns
8A CC machine for thermoplastics
9Nozzle Assemblies
10Plastic Parts
11CC Machine for Ceramics
12(No Transcript)
13Process Machine Design Research
14Movable Side Trowel
15Building Various Surface Slopes
162.5D and 3D Objects
17Slant Wall Fabrication
18Application in Construction
19Why 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 (gt
400,000 / year in US) - Waste and trims are high (3 To 7 tons per average
home 40 of all materials used 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
20What 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 process
45-55 Labor Will be significantly reduced
21(No Transcript)
22Concrete filling
23Insulation
24(No Transcript)
25Construction by Contour CraftingCCC
26Cavities made with CC and filled with concrete
27Creating hollow depositions
28Embedding Reinforcement
29A straight wall builder
30Full scale wall sections
31(No Transcript)
32(No Transcript)
33(No Transcript)
34Conventional Structure Construction
35Adobe structures Ageless comfort and beauty
House of Brojerdi Kashan
36Interior of an Adobe house CalEarth Design
37House made with vaults and domes
Interior of an Adobe house CalEarth Design
38Ingenious methods
39Supportless structures created by CC
40Adobe house Construction
41CRAFT Center for Rapid Automated Fabrication
Technologies
- University of Southern California
- Massachusetts Institute of Technology
- Purdue University
- California State University, Los Angeles
42Grand Challenge
- The grand challenge for CRAFT is building a
custom-designed house in a day while radically
reducing the costs, injuries, waste and
environmental impact associated with traditional
construction techniques. The goal is a revolution
in housing construction, whether it be to
provide - affordable housing for the 30 million U.S.
households facing cost burdens or overcrowding - emergency housing for victims of natural (and/or
man-made) disasters - extraterrestrial buildings constructed from in
situ materials - new styles of housing based on curved rather than
straight surfaces or - inexpensive first ownership housing for an
emerging middle class in the developing world - With national construction-related expenditures
currently totaling close to 1 trillion annually,
the potential impact is enormous.
43Vision and Goals
More broadly the vision is to develop the science
and engineering needed for rapid automated
fabrication of structures of various scales, up
to large objects such as buildings. To achieve
this, CRAFT will develop a unique academic
environment blending fundamental research with
the development of large-scale engineered
systems engineering with computer science and
architecture, and environmental, regulatory,
labor and economic expertise partnerships with
industry and educational and outreach programs.
44(No Transcript)
45Grand Challenge a house in a day
46 Development Phases
47(No Transcript)
48Extraterrestrial Construction
49Deployable CC
50Lunar Construction
51Free-standing Objects / Industrial parts
52Interrelationships among the three research
thrusts
53Extrudable materials fabrication
- Perform underlying basic research necessary to
develop the materials and structures for
automated mega-scale fabrication - Integrate materials into ultra-efficient
structures - Integrate materials with delivery systems and
robots from other thrusts
54Materials to Structures
55Co-extrusion of outer and filler materials A
6DOF Nozzle Assembly
56(No Transcript)
57Faculty
Steve Nutt Materials Science USC
Mike Kassner Aerospace and Mechanical USC
Julian Domaradzki Aerospace and Mechanical USC
Henryk Flashner Aerospace and Mechanical USC
Yan Xiao Civil and Environmental USC
Behrokh Khoshnevis Industrial and Systems USC
George Bekey Computer Science USC
Peter Will ISI USC
Neil Gershenfeld Media Arts and Sciences MIT
Larry Sass Architecture MIT
58Robotics fab, modular components assembly
- Perform research and develop various mono and
distributed robots, tools, software and their
integration into systems for assembling modules
in situ to form functional attributes of
structures - Robots locations, movements and working areas
are dynamically changing along with environment.
Develop a mathematical / geometric model of
environment and a robot coordination protocol. - Perform the fundamental research in the modules
to be placed internal to the extruded material
that transform an extrusion into a functional
wall or roof of a mega-scale structure. The
modules that make a post-modern interactive
structure include - normal reinforcing, plumbing, and electricity
conduits - Integrated communication, interactive sensing and
displays - Integrate the Modules and Assembly Thrust with
Extruded Materials and Software
59Modules and Assemblies
60(No Transcript)
61(No Transcript)
62Automated Painting
63Dynamic Control
64Faculty
George Bekey Computer Science, Electrical Engineering, Biomedical Engineering USC
Peter Will ISI, Industrial and Systems Engineering, Materials Science, Astronautics USC
Phillip Dunston Civil Engineering Purdue
Henryk Flashner Aerospace and Mechanical Engineering USC
Neil Gershenfeld Center for Bits and Atoms MIT
Sami Masri Civil Engineering USC
Maja Mataric Computer Science USC
Gerard Medioni Computer Science USC
Shimon Nof Industrial Science Purdue
Miroslaw Skibniewski Civil engineering Purdue
65Goals
- Perform the fundamental research and develop the
software components for automating mega-scale
fabrication - Integrate components with each other and with
robots from other thrusts
66(No Transcript)
67Faculty
68Four Classes of Software
69Industrial Sectors
- Materials
- Construction
- Equipment
- Software
- Architects
- Real Estate
- Other application sectors
70Industrial Membership
- Industrial membership 3 tiers
- Senior Member - 100,000
- Regular Member - 20,000 to 50,000
- Technology Associate small business
- Benefits to Industry
- Seat on CRAFT ERC industrial advisory board
Senior Member - Licensing (Senior Member exclusive)
- Focused research projects
- Access to cutting edge research
- Access to center facilities and expertise for RD
projects - Contact with graduate students
- Industry-University exchange program
- SBIR and STTR partnerships
- Industry-University Company Day Senior Member
71Expressions of Support
- Materials
- Degussa Corporation (committed)
- Maxit Group (committed)
- CEMEX
- Elotex
- ECRA (European Cement Research Academy)
- VDZ (German Concrete Research Academy)
- Equipment
- Siemens
- John Deere
- Parker-Hannifan
72Expressions of Support
- Construction
- Shea Homes
- Parsons
- Shimizu
- Bechtel
- Boeing (space)
- Government
- NASA (committed)
- U.S. Army
73Expressions of Support
- Architects
- GL Forms (Greg Lynn)
- Gehry Technologies
- Cal-Earth
- Real Estate
- ConAm (builds low income housing in Mexico)
- Regency Outdoor Advertising
74Management Plan
75- Thank you
- please visit
- www.contourcrafting.org