List of next steps and future goals to further this research to a level of base completion
Main goal - Create a concrete extruder using the materials around and accessible to us; students of the University of Virginia. Success
Future Goals - Increase resolution of accuracy when printing - Computer Assisted Toolpath - Accuracy in air pressure in order to ensure even or consistent extrusion rates - Precision in tool dimensions in order to decrease averse affects due to fluid dynamics - Increase in capacity in order to reduce downtime - Create a new methodology of changing out concrete loads
What were the successes and failures, nay opportunities that you encountered when working on these final research projects?
So, successes and failures. Â Let's start with the successes of the concrete extrusion project. Â The first success was creating a concrete mixture that performed in the near exact manner that we wanted, which was a slumpless, quick-curing, and minimal shrinkage concrete. Â The concrete extruded well, and performed exactly as expected. Â A successful test of the exchangeable concrete print heads was executed onsite with the air pressure version of the tool. Â The point at which failures occurred were more extensive and numerous than successes. Â The various toolheads, in addition to success, failed miserably during application, such as when using the custom printed toolhead, the auger system would fail to work because the toolhead wasn't long enough to compensate for the auger's low placement in the barrel. Â The auger system itself failed because the concrete lacked viscosity, the ability to flow, rendering systems based on gravity to fail or become inopportune. Â As well, the drill operators failed to understand the physics and dynamics of an auger, and spun the drill the opposite way for about 10 minutes, tautologically filling the tube instead of extruding its contents. Â The combined auger+air pressure system failed for a myriad of reasons originally unforeseen. Â The excess in tolerance between the auger and the pvc pipe coupled with the air attempting to find the quickest and easiest route out, caused the tube containing the auger to fill with concrete. Â In a typical auger system, this would be favorable. Â However, due to the lack in slump and flow, the concrete instead stayed in place, seemingly unaffected by the auger and gravity. Â This presents itself an opportunity to possibly change augers or auger chambers in order to minimize tolerance and back flow from the concrete and air pressure.
What were your contributions to the final project? Â What were you able to accomplish in our short amount of time?
My contributions to the final project was the organization and delegation of jobs to group members at various meetings. Â This was confirming to Cal what he needed, Ryan where he needed to be, Constance if she needed concrete, Jill to do via computer, Karim what to edit of Jill's, Katie the materials we needed, Luke the objects he had to model. Â And on top of that, I recorded and edited the video, the trailer to the video, the videos for Brian Osborne, the video for the shoe mid-review, the video on OSEH's youtube page, and the video of the robotic's presentation during the Meeting of the Minds.
Where do you feel like this research is going? Â Is it worthwhile to continue? What did you learn from the process you developed in this class? Â How might that inform how to develop further projects/ideation/prototypes for you in your field in the future?
I think the research is going to need to go in the direction of choreography.  The concept is proven to work; we can print concrete with materials we can buy everyday, we have proof of concept.  Now we should strive for evidence of success.  I would propose that research be done in the plausibility of setting up or "making" one of these extruders in under a certain amount of time. --- For example, there exists a concrete world exhibition project in Israel that was unfortunately hit by explosive rounds, however the only damages are on vertical walls.  "Build" a concrete extruder that harnesses the power of [air] in order to inject or extrude a specific concrete mixture into a crevice...  In 15 minutes  --- If the mixture is a constant mix, slumpless and stackable, then what kinds of devices can be used to extrude concrete in a manner similar to the way we want it.
What are you most proud of in this class? Â (Youâve done a lot! Â I am certainly proud of you all!)
I am most proud of the ball and joint that I printed. Â The ball and joint joint, even though it had support material, could be made without it. Â Instead of support material, it could have very small contacts with the model [ball] using the same model material with the model [joint] that could be easily broken and worn away.
