SBIR Phase II: Additive Manufacturing in Construction

This Small Business Innovation Research Phase II project is in support of Branch Technology's novel Additive Manufacturing (AM) process that combines 3D printing technology and conventional construction materials to enable a new way to create buildings. The construction market in the US is approximately 8% of GDP. Any portion of the market that could be enhanced would have a large impact in the US economy. To that end, Branch is creating a process similar to building found in the natural world. In the formation of natural systems, material is the most expensive commodity; a structure is derived by the efficient use of material, but shape is free to be created in almost any form. Branch can approach this efficiency with additive manufacturing, where form is created and material is deposited only when needed and little waste is created. At the core of Branch's method of AM-based construction are three key developments: a three-dimensional freeform structure (the cellular matrix or lattice) which serves as a scaffold for other materials, a robotically- controlled extrusion mechanism by which the cellular matrix is produced, and the algorithms necessary to control the robot for successful production. The proof of concept for this process and more have already been demonstrated by Branch in Phase I of this grant. The technical objectives for Phase II focus on improving the procedures and technology already created. The focus areas for this phase are algorithm development, hardware improvements, the application of finishing materials, code compliance testing, and material science experiments. Algorithm development consists of refining and creating the software necessary to extrude the printed matrix and support a client base. Hardware improvements are necessary to improve the speed and efficiency of the process to create a commercially viable workflow. This research will necessitate the purchase of extra hardware for experimentation. American Society for Testing and Materials (ASTM) testing for load bearing capacity is necessary to enter the market and provide code compliant construction. Experimentation in the application of finished materials to the 3D printed lattice such as spray foam and concrete are vital to the realization of complete buildings.