@PHDTHESIS{20.500.11850-795387, author = {Chadha , Kunaljit}, year = {2025}, publisher = {ETH Zurich}, address = {Zurich}, size = {251 p.}, language = {en}, abstract = {The construction sector significantly contributes to environmental degradation due to its reliance on finite resources for construction materials, high waste generation, and the extensive use of materials such as steel and concrete, which have substantial environmental footprints. To mitigate these impacts, the industry is increasingly exploring Additive Manufacturing (AM) technologies, such as 3D Printing (3DP), using materials such as concrete or earth, as a promising recourse to enhance resource efficiency and reduce material waste, embodied carbon, and environmental impact of construction. However, integrating AM technologies into mainstream construction presents challenges, particularly the inability of materials to support self-weight during printing. This challenge is typically handled by slowing construction rates to allow material drying or chemically accelerating the curing process, which hinders productivity and potentially increases environmental impact. In response to these challenges, this thesis explores the architectural potential of a novel AM method, Impact Printing. Unlike conventional 3DP, Impact Printing involves the discrete aggregation of workable portions of material parts at high velocities and fast cycle times to create volumetric structures through a waste-free, efficient, and automated construction process using low-impact, earth-based materials. This research aims to explore the unique affordances of the Impact Printing method, focusing on its non-contact deposition process, discrete material aggregation, and extended workability window after deposition. The study addresses four key areas: (a) process calibration methods and toolkit to establish a relationship between material properties and machine parameters for effective process control, (b) developing design systems and construction strategies for architectural application and developing approaches for integration with building sub-systems, (c) devising methods to understand system limitations in order to transfer the AM method to more complex on-site robotic platforms, and (d) creating novel robotic tools for formative robotic surface finishing, leveraging the extended workability of materials post-deposition. The developed tools and strategies were validated through 1:1 scale empirical testing in both off-site and on-site scenarios. The outcome of this research contributes to advancing Impact Printing as a viable construction system, expanding the potential of digital design and robotic fabrication, and promoting more sustainable construction practices and the broader field of additive manufacturing.}, keywords = {Construction robotics; Digital Fabrication; Sustainable Design; Advanced Manufacturing Technologies; Architectural design; Automation; Additive Manufacturing}, type = {Doctoral Thesis}, DOI = {https://doi.org/10.3929/ethz-c-000795387}, title = {Impact Printed Architecture. Design Systems, Construction Strategies and Robotic Tools for Impact Printing Method}, Note = {Second Advisor: Dr. Lauren Vasey}, school = {ETH Zurich} }

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