Architects look to 3D-printing for new construction materials
The growing use of 3D printing in construction has architects and engineers exploring new building materials, most commonly mixtures of cement, sand, and plastic-polymers. Dutch firm Dus Architects last summer printed an 86-square-foot cabin in Amsterdam out of recyclable bioplastic. Branch Technologies, founded in 2014 by architect Platt Boyd, has received $750,000 from the US National Science Foundation to try a variety of new building materials for additive manufacturing, including plastic polymers reinforced with carbon fibre and glass, as well as some biopolymers. In December, Branch built a 100 ft by 200 ft lattice-like pavilion for Art Basel in Miami, which was 3D-printed using biodegradable bamboo filament.


Award Abstract # 1632267

SBIR Phase II: Additive Manufacturing in Construction

NSF Org: TI

Translational Impacts

Recipient: BRANCH TECHNOLOGY, INC. Initial Amendment Date: September 11, 2016 Latest Amendment Date: January 22, 2021 Award Number: 1632267 Award Instrument: Standard Grant Program Manager: Rajesh Mehta

rmehta@nsf.gov (703)292-2174

TI Translational Impacts

TIP Dir for Tech, Innovation, & Partnerships Start Date: September 15, 2016 End Date: August 31, 2021 (Estimated) Total Intended Award Amount: $750,000.00 Total Awarded Amount to Date: $1,399,999.00 Funds Obligated to Date: FY 2016 = $750,000.00

FY 2018 = $649,999.00 History of Investigator: Robert Boyd (Principal Investigator)

platt@branchtechnology.co Recipient Sponsored Research Office: Branch Technology LLC

1530 RIVERSIDE DR STE B

CHATTANOOGA

TN US 37406-4313

(334)224-9495 Sponsor Congressional District: 03 Primary Place of Performance: Branch Technology LLC

100 Cherokee Blvd, Suite 125

Chattanooga

TN US 37405-3878 Primary Place of Performance

Congressional District: 03 Unique Entity Identifier (UEI): N4LZEF494YJ8 Parent UEI: NSF Program(s): SBIR Phase II Primary Program Source: 040100 NSF RESEARCH & RELATED ACTIVIT

040100 NSF RESEARCH & RELATED ACTIVIT Program Reference Code(s): 123E, 165E, 169E, 5373, 8029, 9150 Program Element Code(s): 5373 Award Agency Code: 4900 Fund Agency Code: 4900 Assistance Listing Number(s): 47.041

ABSTRACT



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.

PROJECT OUTCOMES REPORT



Disclaimer This Project Outcomes Report for the General Public is displayed verbatim as submitted by the Principal Investigator (PI) for this award. Any opinions, findings, and conclusions or recommendations expressed in this Report are those of the PI and do not necessarily reflect the views of the National Science Foundation; NSF has not approved or endorsed its content. Branch Technology has completed a Phase II and IIB Supplement SBIR award for Additive Manufacturing in Construction. This award funded research to create iterations on Branch's Cellular Fabrication (C-Fab?) process. Built on industrial robotics, geometric algorithms, and a novel "Freeform" extrusion technology that allows printed material to solidify in free space, C-Fab? produces composite construction components that can be tailored for specific applications and product lines. Branch improved its printing technology, digital production and modeling techniques, material portfolio, and industrial workflow through the Phase II scope of this award. With the Phase IIB award, Branch began researching code compliance, building science, and product development initiatives to create commercialized product lines of 3D-printed construction components. This scope resulted in two assemblies that passed the flagship test, National Fire Protection Agency (NFPA) 285 Flame Propagation of Building Exterior Components. Branch also produced and shipped exterior construction panel systems for two buildings in the life of this award - a credit union building's facade in Chattanooga, TN and a parking garage's rainscreen in Huntsville, AL. These two completed projects are proof that commercialization of the technology developed with these awards was successful. In the future, Branch hopes to grow and scale its additive manufacturing and prefabrication operations to produce more projects and continue to streamline construction processes. The company will also develop more product lines and other instances where 3D-printed construction components can economically outperform traditionally-manufactured building products.

Last Modified: 09/08/2021

Modified by: Robert P Boyd Images ( 1 of ) Branch Technology used Cellular Fabrication to additively manufacture the composite panels on the exterior of this building. Branch Technology Copyrighted Robert P Boyd Tennessee Valley Federal Credit Union 3D-Printed Facade

Branch Technology additively manufactured the 260+ unique panels of this facade with Cellular Fabrication. Branch Technology Copyrighted Robert P Boyd Tennessee Valley Federal Credit Union (TVFCU 3D-Printed Facade

Branch Technology used Cellular Fabrication to additively manufacture the large panels on this parking garage. Branch Technology Copyrighted Robert P Boyd Huntsville's Monroe St. Parking Garage 3D-Printed Rainscreen

Branch used Cellular Fabrication to manufacture this pavilion at the OneC1ty Development in Nashville, TN in 2018. It spans 42 feet unsupported and is 21 feet tall. Branch Technology Copyrighted Robert P Boyd The world's largest-spanning 3D printed structure

Branch developed and patented Freeform 3D printing and Cellular Fabrication (C-Fab?). The National Science Foundation's investment in this technology allowed the company to scale operations and build many of the world's largest and most significant 3D-printed structures. Branch Technology Copyrighted Robert P Boyd One of Branch's Freeform 3D printers - the first and largest in the world

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