Expeditionary Large-Scale Freeform Composite 3D Printing for Deployed Environments with Indigenous Materials

Branch Technology is an architectural prefabricator with a patented construction-scale 3D printing process called Cellular Fabrication (C-Fab®). This process combines industrial robotics, proprietary geometric sequencing algorithms, composite material assemblies, and a novel “Freeform” extrusion method that allows printed material to solidify in free space without supports. The resulting products are lightweight, strong, and custom-geometry construction components that perform a variety of functions based on design and product intent. In this project, Branch proposes adapting the above commercial fabrication technology to a specific need for expeditionary in-situ resource utilization (ISRU) in an autonomous manufacturing and construction technology in deployed environments. Branch's 3D printing machines currently operate in a factory setting with high-performance yet commodity materials. Adapting this solution to an expeditionary instance with a possibility for indigenous material use will require significant advancement and technical R&D. Fortunately, Branch has been awarded a contract with NASA for investigating lunar-surface ISRU 3D printing, and through this award has a contract with Stanford University for a biologically-bound soil composite (BSC) that could be in-situ derivable on the moon but also in remote/austere terrestrial environments using locally sourced aggregates and biopolymer binding agent. In this project, Branch proposes to begin Phase I customer discovery and requirement-planning for an expeditionary demonstration of its C-Fab® printers with a possibility of using BSC and terrestrial aggregates like sand as a feedstock. The proposed research tasks include (1) a kickoff meeting with existing interested parties about the defense adaptation, (2), a prioritized list of use cases, (3), physical footprint and size constraint definition, (4) mechanical and hardware adaptation research, and (5) an initial financial proforma of proposed hardware adaptations for a Phase II demonstration. Potential benefits of the technology could include: independence from constraining supply-chains, operational flexibility at deployed environments for construction, manufacturing, restoration and more, and support of strategic USAF initiatives like Agile Combat Employment (ACE), Bomber Strategic Aircraft Recovery Teams (BSART), and more.