Fresh Properties and Autonomous Deposition of Pseudoplastic Cementitious Mortars for Aerial Additive Manufacturing

Barrie Dams; Binling Chen; Yusuf Furkan Kaya; Lachlan Orr; Basaran Bahadir Kocer; Paul Shepherd; Mirko Kovac; Richard J. Ball

doi:10.1109/ACCESS.2024.3373188

IEEE Access (Jan 2024)

Fresh Properties and Autonomous Deposition of Pseudoplastic Cementitious Mortars for Aerial Additive Manufacturing

Barrie Dams,
Binling Chen,
Yusuf Furkan Kaya,
Lachlan Orr,
Basaran Bahadir Kocer,
Paul Shepherd,
Mirko Kovac,
Richard J. Ball

Affiliations

Barrie Dams: ORCiD; Department of Architecture and Civil Engineering, University of Bath, Bath, U.K.
Binling Chen: Department of Architecture and Civil Engineering, University of Bath, Bath, U.K.
Yusuf Furkan Kaya: ORCiD; Department of Aeronautics, Aerial Robotics Laboratory, Imperial College London, London, U.K.
Lachlan Orr: Department of Aeronautics, Aerial Robotics Laboratory, Imperial College London, London, U.K.
Basaran Bahadir Kocer: ORCiD; Department of Aeronautics, Aerial Robotics Laboratory, Imperial College London, London, U.K.
Paul Shepherd: ORCiD; Department of Architecture and Civil Engineering, University of Bath, Bath, U.K.
Mirko Kovac: ORCiD; Department of Aeronautics, Aerial Robotics Laboratory, Imperial College London, London, U.K.
Richard J. Ball: ORCiD; Department of Architecture and Civil Engineering, University of Bath, Bath, U.K.

DOI: https://doi.org/10.1109/ACCESS.2024.3373188
Journal volume & issue: Vol. 12
pp. 34606 – 34631

Abstract

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Additive Manufacturing (AM) in relation to the construction industry is an emerging technology. However, ground-based AM on construction scales may be limited by the dimensions, reach and weight of the ground-based deposition platform. Aerial additive manufacturing (AAM) can revolutionise construction-based AM by employing multiple untethered unmanned aerial vehicles (UAV, known as ‘drones’) depositing material using miniature deposition devices. This study investigates aerial platform and cementitious material requirements for AAM and details development of structurally viable cementitious composite material with suitable rheological properties to demonstrate AAM as a novel aerial approach to complement ground-based activities. A synergistic combination of natural hydrophilic and partially synthetic hygroscopic polymeric hydrocolloids was developed in cementitious material to achieve optimal rheology properties in the fresh state. Analysis involved oscillation and flow tests, calorimetry, microscopy, computed tomography and mechanical tests. AAM application considerations focused on technical characteristics of UAV platforms, flight times, payloads and developed extrusion systems with optimal nozzle dimensions. Results demonstrate critical material parameters of 1700 kg/m3 density, 4° phase angle, 1.1 kPa yield stress, $ < 10$ MPa complex modulus, and the ability to be processed through miniature deposition devices with 500 N force and 250 mA current. Material extrusions were realised using a custom-designed miniature deposition system which a UAV can carry and power. AAM will significantly impact automated construction by enabling new advances in aerial platform applications featuring multiple coordinated agents depositing bespoke material. This is particularly relevant to elevated or challenging construction conditions where an automated aerial approach can crucially reduce safety risks.

Published in IEEE Access

ISSN: 2169-3536 (Online)
Publisher: IEEE
Country of publisher: United States
LCC subjects: Technology: Electrical engineering. Electronics. Nuclear engineering
Website: https://ieeexplore.ieee.org/xpl/RecentIssue.jsp?punumber=6287639

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