Applied Research Associates, a research and engineering firm headquartered in New Mexico, awarded nearly $3.5 million to College of Engineering faculty members to fund a groundbreaking two-year study that aims to revolutionize construction through advanced 3D printing technology.
At the heart of the research lies a critical focus: exploring the most efficient methods of 3D printing to provide horizontal mission structures for the U.S. military. Led by an interdisciplinary faculty team, the study will explore optimal design patterns and locally sourced materials suitable for these construction projects. This includes creating essential structures like culverts, T-walls and Jersey barriers. Moreover, the team seeks to develop precise printing instructions for mobile robots, enabling swift and efficient on-site deployment, thus enhancing construction capabilities.
Leading this research is Michelle Barry, associate professor of civil engineering, who serves as the principal investigator. Assisting her as co-principal investigators are Wenchao Zhou, associate professor of mechanical engineering, and Cameron Murray, associate professor of civil engineering.
Barry’s responsibilities include exploring innovative material structures and geometric configurations to optimize performance and efficiency. The study will also delve into biomimetic structures, drawing inspiration from nature’s designs, such as honeycomb patterns, to reduce material usage while increasing structural strength.
In addition, Barry will catalogue and assess various local soils, evaluating their potential for incorporation into printable concrete. This will enable use of indigenous materials in horizontal construction, mitigating the need for transporting cement and aggregates over long distances. Instead, the team will develop concrete recipes tailored to local conditions, facilitating efficient 3D printing on-site using robotic systems.
Murray, with his expertise in concrete, will analyze the composition of the concrete and conduct large-scale tests on experimental forms.
Overseeing the conversion of CAD models into precise machine instructions is Zhou, director of the Advanced Manufacturing, Modeling and Materials Lab at the U of A, and co-founder of AMBOTS. This involves establishing printing paths for various materials and designs while integrating construction robots.
AMBOTS, a cutting-edge local startup company specializing in “swarm manufacturing technology,” will lead the software development for the 3D printing robots. These advanced robots will adapt to different material mixes for precise, large-scale printing. Moreover, AMBOTS will focus on developing a mobile platform, allowing versatile deployment in diverse environments and optimizing the overall system’s power and efficiency.
The project will involve graduate students from Zhou’s lab and employees from AMBOTS.
With an ambitious two-year timeline for developing a prototype, Barry plans to mobilize up to 18 graduate students, postdoctoral students, research technicians and additional faculty members. The funding from the award will support the acquisition of a large format 3D printer and additional equipment to advance the team’s capabilities to evaluate soil and concrete.
Barry’s interest in using indigenous soils stems from their significantly lower environmental impact. Embracing 3D printing with these materials offers exciting possibilities, she said.
“We can build structures or roads in disaster relief areas where you’re just bringing in a piece of equipment because you might not be able to bring in other construction materials,” she said. “If the local soils will work, you print with them for the time being, people are sheltered and then once it’s not needed, it dissolves back to the original landscape.”
This project provides an exceptional opportunity for AMBOTS to demonstrate its expertise and capabilities. Zhou expressed great enthusiasm for collaborating with Applied Research Associates, leveraging its industry knowledge and experience to drive innovations in swarm 3D printing technology, with far-reaching implications for the future of construction and other industries.
The primary impetus behind the project is to bolster military readiness, emphasizing rapid deployment and cost-effectiveness. However, like many groundbreaking innovations, the technology has potential to help local governments and the private sector in responding to both natural and man-made disasters. This concept could prove invaluable to swiftly build culverts, conduct bridge repairs, address road damages and enhance infrastructure. The versatility and efficiency of this technology opens a wide array of applications with far-reaching benefits.
The $3.5 million subaward is part of a larger $12 million contract the United States Army Engineer Research and Development Center awarded to Applied Research Associates.