Design-Analysis and Development of a Gantry Robot for Multi-Layer 3D Concrete Printing with Simulation and Experimental Validation (2024-07)¶

The present study investigates the design analysis and development of a framed gantry robot (FGR) for 3-D concrete printing. Finite element simulations are performed for design validation and parameter estimation to conduct detailed analysis of the concrete printer. The kinematic and dynamic models of FGR are used for workspace analysis, motion control study, and motor sizing for printer development. The motion trajectory of the printer nozzle tip is evaluated using MATLAB simulations. An integrated programmable logic controller (PLC) with an in-built human-machine interface (HMI) through control algorithms has been implemented for interactive, user-friendly, and precise motion control. A separate control system is developed to monitor the pumping power and feed rate of mortar mix during printing. The simulated control scheme is validated experimentally using trajectory tracking for various input printing paths through HMI, with a maximum tracking error of 1 mm. Successful concrete printing trials have been conducted using various mix-design, following extensive evaluation of different printer and material parameters at the laboratory scale. The proposed design concept, mechanisms, interactive control interface, and tracking accuracy have been validated through simulation and experimental results, for ensuring quality concrete prints by the developed printer. Material testing parameters have been evaluated experimentally for modeling various mix-designs. To further evaluate printing performance, simulations of layer deformation in printed structures are conducted using finite element analysis, incorporating non-linear material models and various contact layer interactions. The simulated results of printed layers of different shapes of structures show a close resemblance with the experimental concrete printing trials.