In an ambitious effort to enhance sustainability in the construction industry, researchers at ETH Zurich have developed a cutting-edge robotic additive manufacturing method that utilizes circular, low-carbon materials. This innovative approach aims to minimize the environmental impact of construction processes and promote the use of Earth-based materials, eliminating the need for cement altogether.The Impact Printing MethodThe heart of this new technique is known as "Impact Printing." This process is designed to construct structures—such as walls—by deploying construction robots that shoot material from above. Upon impact, the materials bond together with only minimal additives required. Unlike conventional concrete 3D printing, this method eliminates the need for pauses during which materials would typically solidify, allowing for a continuous and efficient building process.ETH Zurich's Impact Printing was developed through a collaborative interdisciplinary effort, focusing on increasing the cost competitiveness of sustainable building materials. By employing a high-velocity deposition technique, this method contrasts sharply with traditional layer-based 3D printing. The robots deposit dense material parts at speeds of up to 10 meters per second, achieving effective bonding even in dry joint scenarios, which are often problematic in other construction methods.Advantages Over Traditional MethodsOne of the significant advantages of Impact Printing is its ability to deposit materials in a more stable condition compared to typical extrusion-based processes. This characteristic reduces the dependency on additives to enhance mechanical strength, making the construction process more efficient and environmentally friendly.The development of this technology included the design of a custom printing tool, allowing for integration on multiple high-payload robotic platforms. This versatility means that the construction process can be executed both in offsite production environments and directly on construction sites.The printing tool has been successfully integrated with a high-payload Gantry system at ETH Zurich's Robotic Fabrication Laboratory. Additionally, it can be mounted on an autonomous legged excavator developed by the Robotic Systems Lab, which has demonstrated its capabilities by constructing structures as tall as 3 meters (nearly 10 feet).Future Applications and CustomizationLooking ahead, ETH Zurich researchers envision this technology being deployed in unstructured sites with variable terrain, allowing for the construction of wall structures and essential infrastructure, such as acoustic barriers. The robotic additive manufacturing process enables the production of customizable wall and column structures, addressing the unique needs of each construction project.To further enhance the capabilities of this method, novel software and computational design methods have been developed to facilitate the design and control of the robotic construction process. Although the walls produced through Impact Printing possess a textured surface, methods for robotic surface finishing using ecological plasters are available to achieve high-quality finishes.ETH Zurich's additive manufacturing process has been specifically designed for circular materials with low embodied carbon dioxide (CO2) emissions, utilizing earth-based and excavated materials. A low environmental impact mixture has been formulated by the Chair of Sustainable Construction at ETH Zurich, primarily consisting of locally sourced secondary materials with a minimal amount of mineral admixture. Most materials are sourced from by-products of an industry partner, Eberhard Unternehmungen, recognized as a leader in circular methods within the building sector.ConclusionThe robotic additive manufacturing method developed by ETH Zurich represents a significant advancement in sustainable construction technology. By leveraging local materials and innovative robotic techniques, this method not only addresses the pressing need for environmentally friendly building practices but also holds the promise of customizable and efficient construction processes.
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