Inside Germany’s First 3D Printed Residential Home
German architecture firm Mensa Corte recently constructed an intricate two-story finished 3D printed house to explore the capabilities of large scale additive manufacturing. The experimental build maximizes creative freedom only concrete printing permits while showcasing trailblazing HVAC, plumbing and design integration from the start.
Fused Deposition Printing for a Finished 3D Printed House
Mensa Corte leveraged a COBOD BOD2 gantry style printer to fabricate the home. The system functions via fused deposition printing, precisely extruding layers of specialized concrete vertically and horizontally based on digital model coordinates.
This allows constructing applications like walls, columns, slabs without conventional formwork molds. The positioning equipment and concrete pumping apparatus was assembled onsite by a crane to specifications ensuring robustness across the multi-day fabrication duration.
Understanding the 3D Printing Method
At its core, 3D printing a house involves a computer-controlled machine that deposits material, typically concrete or a concrete-like substance, layer by layer to create walls and other structural elements directly from a digital model. This method, known as additive manufacturing, stands in contrast to the subtractive processes of traditional construction, where materials are cut down and assembled.
The Technology Behind the Print
The printer, often resembling a large crane or robotic arm, is equipped with a nozzle that extrudes the building material. Guided by precise digital blueprints, the printer follows a pre-set path, laying down material with exceptional accuracy. This layer-upon-layer approach not only allows for speed but also enables the creation of complex geometries and forms that would be difficult, if not impossible, to replicate with conventional methods.
Material Matters
The choice of material is critical in 3D printed construction. Most commonly, a special type of concrete mix, designed to flow smoothly through the printer’s nozzle yet quick to set, is used. This material is not just a cornerstone for the structure; it’s a canvas for innovation. Researchers continually experiment with different compositions, including recycled materials and additives, to enhance the sustainability and performance of the print.
From Digital to Physical: The Printing Process
The journey of a 3D printed house begins with a detailed digital model, created using sophisticated design software. This model is not just a visual representation; it’s the blueprint that guides the printer. The printing process is methodical and mesmerizing. The printer’s nozzle moves back and forth, extruding material along predetermined paths. Layer by layer, the walls rise from the ground, with the printer methodically filling in the specified areas.
Speed and Precision
One of the most astonishing aspects of 3D printing houses is the speed. A structure that would traditionally take weeks or months to build can now be printed in a matter of days. This efficiency doesn’t come at the cost of precision. On the contrary, 3D printing offers a level of accuracy that manual processes struggle to match.
Overcoming Challenges
Despite its advantages, the 3D printing process isn’t without challenges. Ensuring the consistency of the material, managing the setting time, and adapting to weather conditions are just a few of the hurdles. Overcoming these requires not only technological solutions but also a deep understanding of the construction principles.
The Transition: From Printing to a Finished 3D Printed House
While the printing process forms the core structure of the house, it’s just the beginning of the journey towards a completed home. The transition from a printed shell to a livable space involves several crucial steps.
Integrating Traditional Methods
Once the printing is complete, traditional construction methods come into play. Roofing, windows, doors, and interior partitions, which are not typically printed, are added using conventional building techniques. This blend of innovative printing with traditional craftsmanship is where the true potential of 3D printed houses shines.
Interior and Exterior Finishing
The finishing touches are what transform a printed structure into a home. Interior finishing involves electrical wiring, plumbing, installation of fixtures, and plastering or painting of walls. On the exterior, facades can be designed to enhance aesthetic appeal while also providing functional benefits like insulation and weatherproofing.
Customization and Personalization
One of the most exciting aspects of 3D printed houses is the scope for customization. The flexibility of the printing process allows for unique design elements to be incorporated directly into the structure. This means that each house can be tailored to the specific needs and preferences of its inhabitants.
Hybrid Printing Approach
While favoring printing directly on the build platform, certain visible yet challenging exterior overhangs were printed offsite then trucked to location for installation post-assembly. This hybrid method blends on-site and off-site fabrication for maximum design flexibility.
Table – Comparison of On-Site and Off-Site Printing
| On-Site Printing | Off-Site Printing | |
| Lead Time | Faster setup | Delayed installation |
| Logistics | No transport | Shipping requirements |
| Geometry | Some constraints | Increased freedom |
The designers aimed to fully embrace 3D printing by rethinking everything from patterns to furniture as printed features rather than solely minimizing post-processing steps.
Wall Integrations
Many walls incorporate spaced cavities for spray foam insulation or hide intricate built-in plumbing and electrical paths keeping lines short and reducing install labor significantly.
Even sections of window frames emerge from the print head as opposed to commonplace post-insertion. This level of MEP coordination requires tremendous pre-planning complexity.
Multi-Material Printing
Printing various concrete grades for textures plus metals or polymers allows tailoring material properties to precise functional needs whether structural, aesthetic or environmental.
For example, a main floor bathroom encloses a completely printed waterproof shower unit plus fireplace – no tiles needed. And the striking sweeping forms crafted would prove impossible for standard construction techniques to emulate economically.
Operating Team
A crew of approximately three oversees the printing process:
- Controlling the printer/material flow
- Monitoring envelope environment
- Pausing the run if any issues
Alongside additional tradesmen fitting components like insulation inside wall voids or wiring conduits through integrated channels between printed layers.
So while automated, skilled assistance smoothens obstacle avoidance.
To Wrap it Up
The pioneering project provides a glimpse into forthcoming realities as large scale additive manufacturing permeates mainstream building industries.
Soon creative visions unrestrained by conventional restraints will rise floor by floor, printed polymer by printed brick. And the once formidable construction tasks of our ancestors may fade into quaint memories of the past.
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