P20652: 3D Concrete Printer
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Project Summary Project Information

Currently, 3-dimensional (3D) concrete printers are used to print large-scale structures such as houses. Small and medium scale prototyping with concrete is currently done using molds which are inaccurate and time consuming. This leaves Multidisciplinary Senior Design (MSD) students at Rochester Institute of Technology (RIT) without an efficient, accurate, cost-effective way to prototype in medium-scale with concrete.

A computer-controlled motion system will be used to deposit prepared concrete along a planned path. The concrete dispenser mechanism moves through space to deposit concrete. The industry standard machine language, G-code, will be implemented. This solution will enable rapid low cost prototyping with concrete by MSD students at RIT.

The primary goal of this project is to design a medium scale 3D concrete printing solution for fast concrete prototyping without molds. This project is expected to have the following benefits.

  • Concrete prototyping tool for RIT MSD students
  • Engineering, teamwork, and design practice
  • Long-term cost savings on molding apparatus
  • Long-term target of printing latrines for disaster relief situations

For an updated project description, click on the following link for the Project Readiness Package.

Our Sponsors:

RIT

RIT

Donated Duet II Wifi and Duex 5 Expansion Board

Donated Duet II Wifi and Duex 5 Expansion Board

Donated PLA filament

Donated PLA filament

Donated concrete supplies

Donated concrete supplies

Team Name
concRIT
Project Name
3D Concrete Printer
Project Number
P20652
Start Term
2019
End Term
2020
Faculty Guide
Bill Nowak, wjnddm@rit.edu
Primary Customer
Sarah Brownell, sabeie@rit.edu
Sponsor (financial support)
RIT (for initial funding)

Team Members

Back row from the left: Alex Kelly, Alexander Pegot Ogier, Nick Claver, Chad tenPas. Front row from the left: Seth Deane, Amiee Jackson, Mary McCombs, Joseph Bragg.

Back row from the left: Alex Kelly, Alexander Pegot Ogier, Nick Claver, Chad tenPas. Front row from the left: Seth Deane, Amiee Jackson, Mary McCombs, Joseph Bragg.

Member Major Role Contact
Alex Kelly CE Co-Project Manager aak3388@rit.edu
Alexander Pegot Ogier ISEE Facilitator axp9827@rit.edu
Nick Claver ME Communicator nvc2527@rit.edu
Chad tenPas ME Purchaser cwt1415@rit.edu
Seth Deane CE Documentation Master sxd4738@rit.edu
Amiee Jackson ME Systems Engineer acj3068@rit.edu
Mary McCombs EE Mediator mxm3224@rit.edu
Joseph Bragg EE Co-Project Manager jdb1677@rit.edu

Work Breakdown: By Phase

MSD I & II MSD I MSD II

Planning & Execution

Project Photos and Videos

Imagine RIT

Gate Reviews

Problem Definition

Systems Design

Preliminary Detailed Design

Detailed Design

Build & Test Prep (1 Dimension)

Subsystem Build & Test (Mixture Development)

Integrated System Build & Test (2 Dimensions)

Customer Handoff & Final Project Documentation

Work Breakdown: By Topic

Project Management Design Tools Design Documentation Implementation Validation Presentation & Dissemination

PRP

Requirements

Schedule Management

Budget Management

Risk Management

MSD I Meeting Notes

MSD II Meeting Notes

Use Case

Machine Benchmarking

Mixture Benchmarking

Functional Decomposition

Morphological Chart

Pugh Concept Selection

BOM

Mechanical Documentation

Electrical Documentation

Software Documentation

Research and Development

Prototyping

Test Plans

Printer Simulation 1

Printer Simulation 1

Performance vs Requirements

Test Results

Design Review Documents

Technical Paper

Poster

Lightning Talk

Acknowledgements

We would like to acknowledge the efforts, time, products, and money contributed to this project by our sponsors.

Every aspect of this project was made possible by the original project sponsorship from the RIT Multidisciplinary Senior Design program. The MSD program serves as a great platform for students to practice their design, critical thinking, resourcefulness, communication, and teamwork skills for a project that serves as the culmination of many student's entire educational career. Thank you to the MSD dept. at RIT.

The Soils and Materials Lab provided the team with a space to test our prototype and develop our concrete mixture. The Lab provided all of the tools necessary for our experiments and the space to spend many hours mixing and testing concrete. Thank you to the Department of Civil Engineering Technology, Environmental Management and Safety.

Our experience with the products provided by the corporate sponsors below has been very valuable. We are proud to recommend to the teams of future iterations of this project, and teams of any project in the MSD program to consider using the products by our sponsors to advance your designs.

The Duet 2 Wifi 3D printer control board provides more functionality and expansion opportunity than any other single component in the project. The RepRap firmware made everyday use easy and enjoyable. The expansion capabilities of the Duet 2 means that this project will be able to grow and change for many years without the limitations that many other control boards would have. Additionally, the online community about the Duet 2 is so well-developed and open that all aspects of board usage from setup, usage, troubleshooting, and expansion were made incredibly easy. Thank you to the team at Duet3D.

The PLA filament donated by 3D Fuel was integral to the prototyping process. Many of the extrusion and structural systems' components for this project were modeled and prototyped to be printed. Sampling the Standard, Workday, and Pro product lines, we can say that the filament produced by 3D Fuel is high quality and high performance for many applications. All of the printed components served the overall design well because of the strength, durability, and flexibility provided by the filaments. Thank you to the team at 3D Fuel.

Manitou Concrete supported the project by providing materials for the early prototyping stage in mixture development. Although the project lacked the scope to thoroughly explore mixture component selection, we are happy to have been apart of the relationship between Manitou and RIT. Thank you to the team at Manitou Concrete.

Additional thanks to Bill Nowak (project guide), who has added design and management experience to the team, and Sarah Brownell (customer), who has added input and guidance to our project all along and provided a workspace for the project to begin, Teresa Wolcott (Soils Lab) for input and guidance about mixture development and Soils Lab usage, and Jan Maneti (Dept. of ME) for providing our team a place to operate and store the printer.