The number of freeform buildings has been continuously increasing, serving as a landmark representing a country or a city. However, most of the freeform buildings have been built with conventional construction methods and required a tremendous amount of construction cost. This study seeks to apply additive manufacturing technologies to the freeform concrete formwork. Among many additive manufacturing techniques, the study focuses on the Laminated Object Manufacturing (LOM) method because of its advantages on building speed and cost. Also, the LOM technique is modified by using sloped angle at the side surface of the laminated layer (called Sloped-LOM or S-LOM), which yields great increase in the accuracy. We built a new FreeForm Formwork 3D Printer (named F3D printer) using the new approach. The F3D printer consists of a 5-axis laser cutting device for sloped cutting of EPS (Expanded Poly-Styrene) sheets with high speed, an auto pallet changer for EPS feeding, and a palletizer for EPS loading. This paper introduces the S-LOM method and the F3D printer, and the comparisons of the outputs from the conventional method and S-LOM method through actual formwork production.
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It is possible to produce irregular structures quickly and accurately using rapid prototyping technology. However, there are still some obstacles in fabricating large-scale structures. In order to overcome these technical hitches, equipment has been developed for manufacturing irregular structures using EPS, making it an easy process. Conventional laser cutting systems can produce undesirable slopes in the structure when cutting EPS due to the divergence of the laser beam, resulting in step differences in the overall shape. Therefore, the objective of this study was to reduce the divergence of the laser beam using a concave lens and to find the optimal cutting conditions of the EPS through cutting experiments. As a result of the study, it was confirmed that the collimated beam cutting system can reduce the cutting slopes compared to the focused beam cutting system. In addition, experimental equations for depth of cut with cutting speed and laser intensity were derived.
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Citations to this article as recorded by
Optimal slope cutting algorithm for EPS free-form formwork manufacturing Harim Kim, Heejae Ahn, Chanwoo Kim, Dongyoun Lee, Taehoon Kim, Yeonho Ko, Hunhee Cho Automation in Construction.2022; 143: 104527. CrossRef
Development of an Adaptive Slicing Algorithm of Laminated Object Manufacturing Based 3D Printing for Freeform Formwork Dongyoun Lee, Junho Hong Buildings.2022; 12(9): 1335. CrossRef
Manufacturing Automation System of Freeform Concrete Formwork Using S-LOM Method Joonhyeok Sim, Hakmin Kim, Kyunwoo Park, Chanwoo Kim, Daehie Hong Journal of the Korean Society for Precision Engineering.2020; 37(1): 43. CrossRef
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