A 04

Integrated Additive Manufacturing Processes for Reinforced Shotcrete 3D Printing (SC3DP) Elements with Precise Surface Quality

Prof. Dr.-Ing. Harald Kloft, Project Leader
Prof. Dr.-Ing. Dirk Lowke, Project Leader
Prof. Dr.-Ing. Klaus Dröder, Project Leader

Dr.-Ing. Abtin Baghdadi
M. Sc. Niklas Freund
M. Sc. Martin David
M. Sc. Robin Dörrie
Dr.-Ing. Inka Mai (geb./b. Dreßler)
M. Sc. Peter Killus
PhD Aileen Vandenberg

Summary of A 04

Within this project, basic research on various SC3DP strategies, materials, tools and methods will be conducted with regard to enhanced material and process control, reinforcement integration, surface quality and automation. To that end, different reinforcement materials in combination with suitable reinforcement manufacturing and integration concepts will be investigated based on force-flow optimised reinforcement alignment. Besides, design strategies as well as material and process control will be investigated in detail. Furthermore, tools and strategies for precise control of the surface quality and geometric resolution of SC3DP elements are subject of research. Finally, strategies, materials and tools elaborated within the project will be synergistically combined and validated at large scale.

Prof. Dr.-Ing. Harald Kloft

leads the scientific staff in the orientation and execution of the design process creation and supports them in an advisory capacity in the creation of test geometries and demonstrators. He is responsible for the content and organisational coordination of all work on the part of ITE.

ite(at)tu-bs.de

Prof. Dr.-Ing. Dirk Lowke

is head of the institute of building materials, concrete construction and fire protection, division of building materials. He will advise the scientific staff executing their work under consideration of the formulated project aims. He is responsible for the coordination and quality control of all work of iBMB.

d.lowke(at)ibmb.tu-bs.de

Prof. Dr.-Ing. Klaus Dröder

advises the scientific staff in continuous consideration of the defined research objectives and investigates opportunities to generate novel research projects and publications. He is responsible for the content and organisational coordination of all work on the part of IWF.

k.droeder(at)tu-braunschweig.de

Dr.-Ing. Abtin Baghdadi

is a research associate at Institute of Structural Design (ITE) of TU Braunschweig. He is responsible for experimental, theoretical and numerical research work as well as for the coordination of the cooperations within the SFB.

a.baghdadi(at)tu-braunschweig.de

M. Sc. Niklas Freund

is a doctoral researcher for the duration of the research project. He will lead and organise the material development and testing program as well as the data evaluation and material modelling work within WG Lowke. Moreover, he will frequently publish the results achieved within the community.

n.Freund(at)ibmb.tu-bs.de

M. Sc. Martin David

is a doctoral researcher at the Institute for Machine Tools and Production Technology (IWF) at TU Braunschweig. He is working on the development of different end effectors for an automated concrete reinforcement as well as the surface processing of printed SC3DP elements. Additionally he is developing different nozzle geometries for the SC3DP process. Moreover, he will frequently publish the results achieved within the community.

m.david(at)tu-braunschweig.de

M. Sc. Felix Gabriel

is a doctoral researcher and Head of research group "Assembly and Production Automation" at the Institute for Machine Tools and Production Technology (IWF) at TU Braunschweig. He will support Prof. Dröder with designing further research topics and will coordinate the work at IWF in the scope of A04.

f.gabriel(at)tu-braunschweig.de

M. Sc. Robin Dörrie

is a doctoral researcher for the duration of the research project. He is leading the A04 project and organising the development of new concepts and strategies for the integration of reinforcement in SC3DP elements. Furthermore he is investigating the SC3DP process, its limitations and the spatial effect for the application in architecture and design within the work group of Prof. Dr.-Ing. Harald Kloft. Moreover, he will frequently publish the results achieved within the community.

r.doerrie(at)tu-braunschweig.de

PhD Aileen Vandenberg

is a postdoctoral researcher specialized in rheology. She will work with the material design and development for the project within the Workgroup of Prof. Dr.-Ing. Dirk Lowke.

a.vandenberg(at)ibmb.tu-bs.de

2020 | Baghdadi, A.; Heristchian, M.; Ledderose, L.; Kloft, H.: Experimental and numerical assessment of new precast concrete connections under bending loads. In: Engineering Structures 212, ELSEVIER.

2020 | Dreßler, I.; Freund, N.; Lowke, D.: The Effect of Accelerator Dosage on Fresh Concrete Properties and on Interlayer Strength in Shotcrete 3D Printing. In: Materials 2020, 13, 374. https://doi.org/10.3390/ma13020374.

2020 | Buswell, R.A.; Leal da Silva; W.R.; Bos, F.P.; Schipper, H.R.; Lowke, D.; Hack, N.; Kloft, H.; Mechtcherine, V.; Wangler, T.; Roussel, N.: A process classification framework for defining and describing Digital Fabrication with Concrete. In: Cement and Concrete Research 134, 2020. https://doi.org/10.1016/j.cemconres.2020.106068.

2020 | Hack, N.; Kloft, H.; Lowke, D.: Additive Fertigung im Bauwesen: 3D-Betondruck als eine Schlüsseltechnologie für die Digitalisierung der Bauwirtschaft. In: Ingenieurbaukunst 2020 – Made in Germany, Jahrbuch der Bundesingenieurkammer, S. 178-183, 2020.

2020 | Freund, N.; Dressler, I.; Lowke, D.: Studying the Bond Properties of Vertical Integrated Short Reinforcement in the Shotcrete 3D Printing Process. In: RILEM Bookseries 28, pp. 612–621.

2020 | Dressler, I.; Freund, N.; Lowke, D.: Control of Stand Properties Produced with Shotcrete 3D Printing by Accelerator Dosage amd Process Parameters. In: RILEM Bookseries 28, pp. 42–52.

2020 | Kloft, H.; Empelmann, M.; Hack, N.; Herrmann, E.; Lowke, D.: Bewehrungsstrategien für den Beton‐3D‐Druck. In: Beton- und Stahlbetonbau. DOI: 10.1002/best.202000032

2020 | Kloft, H.; Krauss, H.-W.; Hack, N.; Herrmann, E.; Neudecker, S.; Varady, P.; Lowke, D.: Influence of process parameters on the interlayer bond strength of concrete elements additive manufactured by Shotcrete 3D Printing (SC3DP). In: Cement and Concrete Research 134, S. 106078. DOI: 10.1016/j.cemconres.2020.106078

2020 | Kloft, H.; Empelmann, M.; Oettel, V.; Ledderose, L.: 3D Concrete Printing - Production of first 3D Printed Concrete Columns and Reinforced Concrete Columns. In: BFT International, no. 6, pp. 28-37.

2018 | Krauss, H.-W.; Nolte, N.; Budelmann, H.; Kloft, H.; Lowke, D.: Concrete Additive Manufacturing – challenges and solutions illustrated by the SC3DP process. In: 20. Ibausil, Weimar, 9 pp.

2018 | Lowke, D.: Thixotropy of SCC - A model describing the effect of particle packing and superplasticizer adsorption on thixotropic structural build-up of the mortar phase based on interparticle interactions. In: Cem. Con. Res., Vol. 104, pp. 94-104.

2018 | Lowke, D.; et al.: Particle-bed 3D printing in concrete construction – possibilities and challenges. In: Cem. Con. Res., Vol. 112, pp. 50-65.

2018 | Nolte, N.; Varady, P.; Krauss, H.-W.; Lowke, D.: Schichtenverbund bei der additiven Fertigung – Einflussgrößen und Verfahrensvergleich. In: 20. Ibausil, Weimar, 8 pp.

2018 | Herrmann, E.; Lindemann, H.; Kloft, H.: Entwicklung einer robotergestützten Spritzbetontechnologie zur schalungslosen generativen Fertigung komplexer Betonbauteile. In: Proc. Spritzbeton-Tagung, Alpbach.

2018 | Kloft, H.; et al.: Digital fabrication as chance for a “New Standard” in concrete design. In: ICCDF 2018, Zürich.

2018 | Lindemann, H.; et al.: Development of a Shotcrete 3D-Printing (SC3DP) technology for additive manufacturing of reinforced freeform concrete structures. In: ICCDF 2018, Zürich.

2017 | Dröder, K.; et al.: Incremental manufacturing: Design aspects of flexible hybrid manufacturing cells for multi-scale production. In: 7. WGP-Jahres-Kongress, Aachen.

2016 | Neudecker, S.; Bruns, C.; Gerbers, R.; Heyn, J.; Dietrich, F.; Raatz, A.; Kloft, H.: A new robotic spray technology for generative manufacturing of com- plex concrete structures without formwork. In: Proc. CIRP, Vol. 43, pp. 333-338.

2016 | Dröder, K.; et al.: Partial additive manufacturing: experiments and prospects with regard to large series production. In: Proc. CIRP, Vol. 55, pp. 122- 127.