{"id":84921,"date":"2020-11-05T09:06:45","date_gmt":"2020-11-05T09:06:45","guid":{"rendered":"https:\/\/www.pbctoday.co.uk\/news\/?p=84921"},"modified":"2020-11-05T09:17:27","modified_gmt":"2020-11-05T09:17:27","slug":"offsite-3d-printing","status":"publish","type":"post","link":"https:\/\/www.pbctoday.co.uk\/news\/mmc-news\/offsite-3d-printing\/84921\/","title":{"rendered":"Offsite construction with lightweight 3D printing"},"content":{"rendered":"

When you think of 3D printing buildings, you probably picture giant outdoor robot gantries \u201cpooping out concrete\u201d, as John McCabe of Branch Technology<\/a> puts it. Layer upon layer, gradually building up the walls \u201cas has been done for millennia\u201d \u2014 only now with robotics<\/h2>\n

Branch Technology does 3D printing<\/a> very differently, starting with printing offsite. \u201cPrinting onsite adds chaos, where there\u2019s already a lot of safety issues,\u201d says McCabe.<\/p>\n

Branch\u2019s facility is far from chaotic \u2014 it\u2019s a precise robotic ballet, with multiple projects being coordinated at the same time.<\/p>\n

\u201cIn our facility, we have 12-foot robots printing a range of different types and scales of projects. One might be working on part of a parking deck, and another might be working on a bank, while another is printing something for the Department of Defense.\u201d<\/p>\n

Special structures<\/h3>\n

The structures that Branch robots print are also very different from layers of undifferentiated concrete. They are complex lattices that can be manufactured from various substances, have many different shapes and sizes, and be filled with different materials.<\/p>\n

\u201cThink about it. Very few buildings are made of only one type of material,\u201d says McCabe.<\/p>\n

\u201cBranch processes can combine complementary materials, increasing the resulting building\u2019s capabilities and adding value for the client.\u201d<\/p>\n

Branch\u2019s 3D printing \u201cuses 20 times less material than other 3D printing methods, with almost no waste\u201d and the resulting structures are many times lighter than a similar size structure printed with concrete. Although they\u2019re light, the structures are designed for strength too.<\/p>\n

\u201cA matrix we print that\u2019s the size of a concrete block \u2014 but which is 90% air \u2014 will hold 2000-3000 pounds of compressive force,\u201d explains McCabe.<\/p>\n

\u201cWhen we fill that space with a customised foam, we can get almost 10,000 pounds of compressive strength.\u201d<\/p>\n

The lattice structures can be filled with various materials with different properties such as sound attenuation or thermal insulation. Sensors can be embedded within the materials to create a smart building.<\/p>\n

Branch has printed a 3,000 square foot single story house. McCabe says it\u2019ll be a few years before they can focus on building tall, self-supporting structures because the materials currently can\u2019t compete with the capabilities of steel. \u201cFor the same reason, it\u2019ll also be a long time before 3D printing with concrete can build taller than one storey.\u201d<\/p>\n

Founding and focus<\/h3>\n

How was Branch founded? In 2013, there was a Kickstarter project for a 3D printing pen that could print in midair. Branch founder and chief executive officer, Platt Boyd, bought one and played around with it, attaching it to mini-robots. He decided the idea had commercial potential in the construction industry<\/a>, left the architecture firm where he\u2019d worked for over 15 years, and moved to Chattanooga to found Branch (Chattanooga and the surrounding area is a hotbed for innovation, especially in advanced manufacturing).<\/p>\n

\u201cThe company was embraced by the Chattanooga startup culture and the first employees were rockstars who came here from places like New York City and Boston. For the most part, they\u2019re still here,\u201d says McCabe. \u201cWe now have about 30 people working here and they\u2019re the smartest group of people I\u2019ve ever had the good fortune to work with.\u201d<\/p>\n

Because 3D printing is so versatile, Branch often received requests to make random things. But Boyd decided they needed to focus and the company went all-in on developing 3D printed fa\u00e7ades. \u201cThey\u2019re a great non-structural way to add a signature look to a building while still embracing the traditional construction trades.\u201d<\/p>\n

Labour<\/h3>\n

It\u2019s a persistent refrain that it\u2019s hard to hire young people to work in the construction industry<\/a>, and labour shortages are a major problem. But working in the Branch facility is a far cry from a typical construction environment and Branch hasn\u2019t had hiring problems.<\/p>\n

\u201cConstruction companies can\u2019t find talent,\u201d says McCabe.<\/p>\n

\u201cI\u2019m privileged to work with a large, diverse group of young people who are very excited about robotics and the future of construction. They want to work in this industry.\u201d<\/p>\n

Off-world construction<\/h3>\n

Branch has a team focused on developing solutions for the Department of Defense. \u201cWe\u2019ve been taking speculative ideas and creating advanced manufactured products to fit their customised need,\u201d says McCabe.<\/p>\n

\u201cThe kind of project ranges from a logistics solution for high-tech equipment, a building fa\u00e7ade for onsite housing, or lightweight EMP-hardened expeditionary structures.\u201d<\/p>\n

They also work with the Air Force and the Space Force, leaning into this since 2017 when, out of a field of 77 global competitors, Branch won first place in the NASA Martian Habitat Challenge. The material they co-developed for printing the Martian habitat was the equivalent of 70% Martian soil, mixed with 30% recyclable mission waste such as bags and parachutes.<\/p>\n

\u201cThe Space Force is expanding their knowledge and capabilities in off-world construction. We\u2019ve been involved in developing zero-g and other-world concepts to save fuel and time, as well as to protect our service-people and equipment from harm.\u201d<\/p>\n

The future<\/h3>\n

Branch is partnering with real estate companies, developers, construction companies, and architecture firms. McCabe says that small companies trying to make their mark, as well as big companies looking for efficiencies, see value in Branch\u2019s work.<\/p>\n

\u201cIn the long term, we want a distributed factory network around the world that can print, fill, and finish structural and non-structural components for buildings of all scales,\u201d says McCabe.<\/p>\n

\u201cWe have a roadmap to get there. We have some great partnerships in the pipeline and it\u2019s going to blow some minds when we can finally talk about them!\u201d<\/p>\n

 <\/p>\n

 <\/p>\n

Zena Ryder is a freelance writer, specializing in writing about construction. You can find her at Zena, Freelance Writer<\/a> and on LinkedIn<\/a>.<\/em><\/p>\n

This article was first published in the November\/December 2020 Edition of MBI\u2019s Modular Advantage magazine<\/a>.<\/em><\/p>\n

 <\/p>\n

Modular Building Institute<\/strong><\/p>\n

www.modular.org\/<\/a><\/p>\n

Twitter: @rethinkmodular<\/a><\/p>\n

LinkedIn: Modular Building Institute<\/a><\/p>\n

\n<\/div>","protected":false},"excerpt":{"rendered":"

When you think of 3D printing buildings, you probably picture giant outdoor robot gantries \u201cpooping out concrete\u201d, as John McCabe of Branch Technology puts it. Branch Technology does 3D printing very differently, starting with printing offsite.<\/p>\n","protected":false},"author":16,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"footnotes":""},"categories":[942],"tags":[862,676,856,916,627,696,50224],"stakeholder_rel_tag":[172484],"contributor_rel_tag":[],"class_list":{"0":"post-84921","1":"post","2":"type-post","3":"status-publish","4":"format-standard","6":"category-mmc-news","7":"tag-3d-printing","8":"tag-construction","9":"tag-construction-technology","10":"tag-modern-methods-of-construction","11":"tag-modular-construction","12":"tag-offsite-construction","13":"tag-sh-modular-building-institute","14":"stakeholder_rel_tag-modular-building-institute"},"acf":[],"yoast_head":"\nOffsite construction with lightweight 3D printing<\/title>\n<meta name=\"description\" content=\"When you think of 3D printing buildings, you picture giant outdoor robot gantries \u201cpooping out concrete\u201d, as John McCabe of Branch Technology puts it\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.pbctoday.co.uk\/news\/mmc-news\/offsite-3d-printing\/84921\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Offsite construction with lightweight 3D printing\" \/>\n<meta property=\"og:description\" content=\"When you think of 3D printing buildings, you probably picture giant outdoor robot gantries \u201cpooping out concrete\u201d, as John McCabe of Branch Technology puts it. 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