The number of freeform buildings has been continuously increasing, serving as a landmark representing a country or a city. However, most of the freeform buildings have been built with conventional construction methods and required a tremendous amount of construction cost. This study seeks to apply additive manufacturing technologies to the freeform concrete formwork. Among many additive manufacturing techniques, the study focuses on the Laminated Object Manufacturing (LOM) method because of its advantages on building speed and cost. Also, the LOM technique is modified by using sloped angle at the side surface of the laminated layer (called Sloped-LOM or S-LOM), which yields great increase in the accuracy. We built a new FreeForm Formwork 3D Printer (named F3D printer) using the new approach. The F3D printer consists of a 5-axis laser cutting device for sloped cutting of EPS (Expanded Poly-Styrene) sheets with high speed, an auto pallet changer for EPS feeding, and a palletizer for EPS loading. This paper introduces the S-LOM method and the F3D printer, and the comparisons of the outputs from the conventional method and S-LOM method through actual formwork production.
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It is possible to produce irregular structures quickly and accurately using rapid prototyping technology. However, there are still some obstacles in fabricating large-scale structures. In order to overcome these technical hitches, equipment has been developed for manufacturing irregular structures using EPS, making it an easy process. Conventional laser cutting systems can produce undesirable slopes in the structure when cutting EPS due to the divergence of the laser beam, resulting in step differences in the overall shape. Therefore, the objective of this study was to reduce the divergence of the laser beam using a concave lens and to find the optimal cutting conditions of the EPS through cutting experiments. As a result of the study, it was confirmed that the collimated beam cutting system can reduce the cutting slopes compared to the focused beam cutting system. In addition, experimental equations for depth of cut with cutting speed and laser intensity were derived.
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Additive Manufacturing (AM) techniques have been applied to many fields. Among them, the Fused Deposition Method (FDM) has been utilized in construction application with concrete paste instead of plastic resin. This paper presents feasibility study of applying Laminated Object Manufacturing (LOM) process especially for freeform architecture. We developed 3D printer of LOM technique equipped with sloped cutting capability. In that way, the surface quality can be improved even with thick laminated sheets. The feasibility of this novel approach was proved through building a freeform bench, and comparing its building time and manufactured freeform surface quality.
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A Study on Optimal Cutting Condition of EPS Foam Cutting Based on Collimated CO2 Laser Beam Hakmin Kim, Joonhyeok Sim, Sangyeol Jeong, Daehie Hong Journal of the Korean Society for Precision Engineering.2019; 36(9): 859. CrossRef
Precise installation of a seam clamp is crucial as failure to do so will lead to defects, compromising the quality of paper containers. Even experts spend 90-120 minutes, which comprises 4.7 percent -6.25 percent of the replacement and adjustment process on a paper container manufacturing machine. To overcome an undesirable replacement procedure, a composite seam clamp was devised. The objective of this paper is to enhance the quality of a seam of a paper container and reduce time replacing seam clamps. The composite seam clamp was designed based on the Guerin process. Silicon rubber, which can be used in the temperature range of the paper container manufacturing process (110-130℃), was selected. To validate performance of the steel and composite seam clamp, 13 error situations resulted from translation and rotating misalignment of seam clamps were set and simulated. Through FEM (Finite Element Method) simulation, this paper confirms that the composite seam clamp shows higher transmission of clamping pressure compared to steel seam clamps in error situations. The feasibility of the composite seam clamp was validated in reducing replacement time of seam clamps through on-site tests.
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