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Additive manufacturing evolution in construction: From individual terrestrial to collective, aerial, and extraterrestrial applications
Journal article   Peer reviewed

Additive manufacturing evolution in construction: From individual terrestrial to collective, aerial, and extraterrestrial applications

Kamran Aghaee, Linfei Li, Alireza Roshan and Parsa Namakiaraghi
Journal of Building Engineering, v 96, 110389
01 Nov 2024

Abstract

3D printing Additive manufacturing Aerial Automation in construction Bio-inspired additive manufacturing Collective robotic construction Lunar Testing methods Topology optimization
The third industrial revolution is marked by the fast-growing evolution of Additive Manufacturing (AM) in construction. This transformative shift is driving the automation of construction processes to bestow economic, sustainable, and functional habitats on earth and space. AM has enabled innovative manipulation and design of materials, architectures, and structures in the construction industry. The feasibility of using a diverse range of both original and recycled materials, freeform architecture, topology optimization and bio-inspired design, manufacturing precision, minimal production time and labor, has effectively advanced the objectives. This has resulted in a substantial reduction in costs while simultaneously enhancing safety, sustainability, and functionality of AM in construction. To fulfill the automation in construction objectives, AM trajectory is advancing from off-site toward on-site construction by upscaling, collective robotic work, remote, aerial, and lunar construction. Despite design challenges related to factors like reinforcement, bonding at layer interfaces, rheology adjustment, and cracking resistance, along with practical considerations including cost, harmonized/synchronized robotic function, drone stability, and precision in deposition, AM is making remarkable advancements that surpass expectations. Looking forward, bee-sized drones may be witnessed swarming to construct structures in diverse environments, including remote areas on Earth and in space. Given these developments, this study reviews the advancement of AM in the construction industry, tracing its evolution from individual terrestrial to collective, aerial and extraterrestrial construction. In addition, the most suitable AM techniques encompassing bio-inspired technology and topology optimization are elaborated. Preferred materials and their characteristics for terrestrial, aerial, and extraterrestrial construction, as well as pavement repair are discussed. Furthermore, appropriate testing methods are introduced, and the challenges and limitations associated with AM construction on terrestrial, aerial, and lunar surfaces with insights for the future of AM are elucidated. [Display omitted] •Novel AM techniques, including collective, aerial, and lunar, as well as nature-inspired designs and topology optimization, are demonstrated.•Materials considerations for multi-scale construction are explained.•Design challenges are addressed and solutions such as bio-inspired design, magnetorheology, and topology optimization are proposed.•Appropriate testing methods for measuring critical aspects of AM in building and road construction are recommended.•The future directions of AM in terrestrial and extraterrestrial applications are outlined.

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Collaboration types
Domestic collaboration
Web of Science research areas
Construction & Building Technology
Engineering, Civil
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