A 05

Integration of Individualized Prefabricated Fibre Reinforcement in Additive Manufacturing with Concrete

Prof. Dr. sc. ETH Zurich Dipl. Ing. M.A. AA Norman Hack, Project Leader
Prof. Dr.-Ing. Christian Hühne, Project Leader

M. Sc. Stefan Gantner
M. Sc. Tom Rothe

Summary of A 05

One of the biggest challenges in 3D printing with cementitious materials is the integration of reinforcement. As 3D-printed, unreinforced concrete components can only compensate for limited tensile forces, their range of applications is confined to predominantly compression-stressed components and thus the structural potential of 3D-printed parts remains unrealized. The aim of this project is to develop textile-based reinforcement strategies for additive manufacturing with concrete and to utilize the advantages of textile reinforcement (e.g. corrosion resistance and material flexibility) for the production of material-efficient, individualized structures.

Prof. Dr. sc. ETH Zurich Dipl. Ing. M.A. AA Norman Hack

is supervising ITE`s requested doctoral researcher during all phases of the research. Additionally, he will be actively involved in the conceptual phase, developing reinforcement concepts for the different AM methods.

n.hack(at)tu-braunschweig.de

Prof. Dr.-Ing. Christian Hühne

leads the iAF scientific staff in the development and construction of the winding head, the manufacturing process of the reinforcement from FRP with different curing resins, and in questions of the damage of the FRP by the shotcreting process.

christian.huehne(at)tu-braunschweig.de

M. Sc. Stefan Gantner

investigates fibre reinforcement strategies as doctoral researcher. In collaboration with project partners he develops techniques for processing fibres to obtain suitable reinforcement structures for different AM methods. Beyond conception his work scope ranges from deriving representative part designs to physical testing including prototyping of toolings.

stefan.gantner(at)tu-braunschweig.de

M. Sc. Tom Rothe

is investigating the usability of prefabricated fibre reinforcement produced in a robotic winding process for different AM methods. He’s developing an automated production process of the fibre reinforcement for the special needs of the project. This includes the investigation of the most suitable reinforcement geometry, the build-up of a dynamic winding machine and the integration of it into a robotic winding process.

t.rothe(at)tu-braunschweig.de

2021 | Hack, N.; Bahar, M.; Hühne, C.; Lopez, W.; Gantner, S.; Khader, N.; Rothe, T.: Development of a Robot-Based Multi-Directional Dynamic Fiber Winding Process for Additive Manufacturing Using Shotcrete 3D Printing. In: Fibers 2021, 9, 39, 2021. https://doi.org/10.3390/fib9060039.

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.

2018 | Hack, N.: Mesh Mould: A Robotically Fabricated Structural Stay-in-Place Formwork System. ETH Zurich.

2018 | Buchli, J.; et. al.: Digital in situ fabrication - Challenges and opportunities for robotic in situ fabrication in architecture, construction, and beyond. In: Cement and Concrete Research, vol. 112. pp. 66–75.

2016 | Niemann, S.; Hühne, C.; et. al.: Anisogrid Design for Fuselage Primary Structures – Results of EU/RU projects ALaSCA and PoLaRBEAR. In: Proceedings of the 5th Aircraft Structural Design Conference, Manchester.

2016 | Kappel, E.; Hühne, C.: Fertigungsinduzierte Deformationen von Hochleistungsverbundstrukturen. In: Lightweight Design 9 (2), S. 22–29. DOI: 10.1007/s35725-016-0005-0.

2015 | Düring, D.; Weiß, L.; Stefaniak, D.; Jordan, N.; Hühne, C.: Low-velocity impact response of composite laminates with steel and elastomer protective layer. In: Composite Structures 134, S. 18–26. DOI: 10.1016/j.compstruct.2015.08.001.

2015 | Hühne, C.; Ückert, C.; Steffen, O.: Entwicklung einer laminaren Flügelschale. In: Lightweight Design 8 (6), S. 32–37. DOI: 10.1007/s35725-015-0054-9.

2013 | Hack, N.; Lauer, W.; Langenberg, S.; Gramazio, F.; Kohler, M.: Overcoming repetition: Robotic fabrication processes at a large scale. In: Int. J. Archit. Comput., vol. 11, no. 3.

2010 | Ernst, G.; Vogler, M.; Hühne, C.; Rolfes, R.: Multiscale progressive failure analysis of textile composites. In: Composites Science and Technology 70 (1), S. 61– 72. DOI: 10.1016/j.compscitech.2009.09.006.