3D-Printed vs Injection Molded Vortex Modular Roundabout Components for a New Turbo Configuration

ZKxKZ will develop and demonstrate two competing approaches for a modular plastic turbo-roundabout system. First, our baseline solution will be our current Vortex Roundabout commercial product. Vortex provides a LEGO®-like modular kit for customized for each intersection by CNC-machining units from large injection-molded recycled plastic boards. Modules anchor onto existing roadway using a patented energy-absorbing anchor and plug. Commercial Vortex installations have received multiple State and National innovation awards from the road construction industry. Second, we will compare a new approach, replacing Vortex’s molded/CNCed modules with large- 3D-printed modules. 3D-printing offers many potential advantages over molding, including faster time between drawings and module production, elimination of costly tooling and CNC-machining, and infinite shape flexibility. Phase I will physically produce and test molded verses 3D-printed full-scale modules in the lab and installed on road surfaces. Cost and installation time will be compared. We will also start searching for a prototype turbo-roundabout installation site for our Phase II demonstration unit. The current Vortex system reduces roundabout cost and installation time by >50% compared to conventional concrete construction. Our goal will be to remove significant additional cost and time from the already impressive modular Vortex performance via 3D printing.