61KVqdwpD6L._AC_UL160_SR160,160_ How Concrete Homes Are Built With A 3D Printer | Insider Art

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Are you curious about how concrete homes can be built using a 3D printer? In this Insider Art video, Aiman Hussein, a concrete-3D-printer operator at Alquist, will guide you through the fascinating process. Alquist is a company that uses 3D-printing technology to construct affordable homes and reduce the cost of housing in economically distressed communities. You will get an insider’s look at the printing process, the setup involved, and even a walkthrough of a completed home. Stay tuned to learn more about this innovative approach to construction.

Table of Contents

The Process of Building Concrete Homes with a 3D Printer

Setting up the Printer on Site

When setting up the printer on-site, the process begins by working on a slab or a ribbon footing. The printer is then positioned around the area where the house is going to be constructed. In terms of equipment, there are typically five or six pieces involved, including the printer itself and a control panel for operating and monitoring the print settings. On the material side, there is a silo that holds the dry material, as well as a mixing system and a pumping system. The water is added during the mixing process and then pumped through a hose, which feeds the printer material. The process of setting up the printer on-site is similar to setting up a typical desktop 3D printer.

Equipment and Material Setup

The equipment setup for building concrete homes with a 3D printer includes the printer itself, a control panel, a silo for the dry material, and a mixing and pumping system for adding water. The printer is placed on a slab or ribbon footing, and the control panel is used to operate and monitor the print settings. The silo holds the dry material, which is then mixed with water in the mixing system. The water is pumped through a hose and fed into the printer, where it is used to create the concrete material for printing the walls of the house.

Designing the CAD File

Before printing can begin, a CAD (Computer-Aided Design) file needs to be created. This file tells the 3D printer where to go, how fast to move, and how much material to release at each specific spot. The CAD file is essentially the blueprint for the house, providing the printer with the necessary instructions to construct the walls. The printer follows the centerline of the CAD file throughout the entire printing process. It reads the file as a cross-section, similar to cutting out a thin line of the object being printed. This cross-section is then repeated multiple times to build up the layers and complete the house.

Printing the Walls and Creating Cavities

Once the printer is set up and the CAD file is created, the printing process can begin. The printer moves along the centerline of the CAD file, layer by layer, to build up the walls of the house. The two rails of the printer provide the outer bounds for the walls, while the middle portion allows space for running electrical and plumbing systems. To create cavities for doors, the printer splits the house into two wall sections, one on the left side of the door and one on the right side. It lifts up, moves to the other side of the door, and completes the other wall section. A steel lintel is added above the door as a manual support, allowing the printer to continue printing directly over it.

Layering and Setting Time

Each house consists of approximately 150 layers, with each layer being around three-quarters of an inch thick. This thickness results in a standard 9-foot wall height. Once a layer is printed, it takes around five to 10 minutes for it to set before another layer can be added on top. The set time refers to the time required for the printed material to harden enough to support the weight of another layer. After the walls are printed, it is recommended to wait for approximately two weeks before adding any large load-bearing weight, such as a roof system. This allows the concrete to reach its maximum strength, which typically occurs at around 28 days.

Customizable Nozzle Design

In the 3D construction industry, the nozzle design for the printer is highly customizable. There are different nozzle options available, each with its own aesthetic and structural properties. One type of nozzle has a squared-off shape, resulting in a flat and smooth finish. Another type has a rounder shape, leaving a more textured and bead-like appearance. The structural design of both nozzle types is similar, with the difference lying mainly in the aesthetic finish they create. Additionally, the thickness of the nozzle can be adjusted to increase the amount of concrete in the wall, resulting in a more structurally robust wall if desired.

Comparison to Brick-Laying System

The process of building concrete homes with a 3D printer can be likened to a brick-laying system, where one layer of bricks is laid, and then the next layer is built on top. However, there are significant differences in terms of building materials and labor intensity. While a brick-laying system requires manual labor to lay the bricks, a 3D printer constructs all the walls, guiding general contractors (GCs) through the installation of doors, windows, HVAC, and plumbing systems. The use of a 3D printer allows for more efficient construction and eliminates the need for extensive manual labor.

Advantages of 3D-Printed Homes

Quicker Construction

One of the major advantages of 3D-printed homes is the speed of construction. The process of printing the walls layer by layer is much faster compared to traditional construction methods. Each layer can be completed within a matter of minutes, allowing for the rapid construction of the entire house. This quick construction time is beneficial in addressing the urgent need for affordable housing in economically distressed and underserved communities.

Cost Efficiency

3D-printed homes offer cost efficiency in multiple ways. The use of a 3D printer reduces the need for manual labor, which can significantly decrease construction costs. Additionally, the ability to print completed walls eliminates the need for additional materials and resources required in traditional construction methods. The cost savings achieved through 3D printing technology can contribute to making housing more affordable for individuals and communities with limited financial resources.

Durability and Energy Efficiency

Concrete is a highly durable and resilient building material, and 3D-printed homes benefit from this inherent strength. The solid walls created through the printing process provide stability and longevity, ensuring the longevity of the structure. Furthermore, 3D-printed homes can be designed to incorporate energy-efficient features, such as thermal insulation and efficient HVAC systems. These energy-saving elements contribute to reduced utility costs, making the homes more sustainable and affordable for occupants in the long run.

Addressing Job Concerns

Focus on Local Hiring

One of the major concerns surrounding the use of 3D printing technology in construction is the potential loss of manual labor jobs. However, Alquist and other companies in the industry are committed to addressing this concern by focusing on local hiring. When the companies set up operations in a community, they prioritize hiring local individuals and provide training on operating the printers. This approach ensures that the technology creates new job opportunities within the community rather than displacing existing manual labor.

Collaboration with Universities for Job Training

To further address job concerns, companies like Alquist are collaborating with universities to develop job training programs. These programs aim to equip individuals with the skills and knowledge required to work with 3D printing technology in the construction industry. By partnering with educational institutions, companies can contribute to the development of a skilled workforce that can adapt to the changing needs of the construction sector.

Conclusion

The process of building concrete homes with a 3D printer offers numerous advantages, including quicker construction, cost efficiency, durability, and energy efficiency. By utilizing large-scale 3D printers, companies like Alquist can create affordable housing in economically distressed and underserved communities. Concerns about job displacement are addressed through a focus on local hiring and collaboration with universities for job training. Overall, 3D-printed homes have the potential to make a positive impact in the construction industry, providing affordable and sustainable housing options for communities in need.

Aiman Hussein, a concrete-3D-printer operator, works for Alquist. Their goal is to use 3D-printing technology to construct homes and reduce the cost of housing and infrastructure in economically distressed and underserved communities. In this video, Aiman will guide you through the process, showcasing the printing, his setup, and a walkthrough of a completed home.

For more information, visit: Alquist

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