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D-Shape

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D-Shape is a large 3-dimensional printer that uses binder-jetting, a layer-by-layer printing process, to bind sand with an inorganic seawater and magnesium-based binder in order to create stone-like objects. Invented by Enrico Dini, founder of Monolite UK Ltd, the first model of the D-Shape printer used epoxy resin, commonly used as an adhesive in the construction of skis, cars, and airplanes, as a binder. Dini patented this model in 2006. After experiencing problems with the epoxy, Dini changed the binder to the current magnesium-based one and patented the printer again in September 2008. In the future Dini aims to use the printer to create full-scale buildings.

Technical description

The current version of the D-Shape 3-D printer sits in a 6 m by 6 m aluminium frame. The frame consists of a square base that moves upwards along four vertical beams during the printing process. Stepper motors on each beam control this movement, allowing precise positioning and holding at specific heights. A printer head, spanning the full 6-meter horizontal length of the base, contains 300 nozzles spaced 20 millimeters apart. An aluminum beam runs perpendicular to the printer head, connecting it to the base.

Process

Before the actual printing process can begin, a 3-D model of the object to be printed must be created using CAD, a software that allows a designer to create 3-D models on a computer. Once the model is finished, the CAD file is sent to the printer head. The printing process begins when a layer of sand, 5 to 10 mm thick, mixed with solid magnesium oxide (MgO), is evenly distributed by the printer head in the area enclosed by the frame. The printer head breaks the 3-D model into 2-D slices. Then, starting with the bottom slice, the head moves across the base and deposits an inorganic binding liquid made up of a solution that includes magnesium chloride, at a resolution of 25 DPI (1.0 mm). The binder and sand chemically react to form a sandstone material. It takes about 24 hours for the material to completely solidify. The material resembles, by composition, Sorel cement.

The 20 mm gap between the nozzles may require filling. An electric piston on the beam holding the printer head shifts the head in a direction perpendicular to the printer’s motion to fill these gaps and provide consistent exposure of the sand to the binder. D-Shape completes each layer with four forward and backward strokes. Stepper motors on the vertical beams adjust the base upwards after a layer is completed. The hollow framework above the printer head is refilled cyclically, distributing new sand into the frame to form the next layer. During the printing process, excess sand supports the solidifying material and can be reused for subsequent printings. The process continues uninterrupted until the desired structure is fully printed.

After the printer is done with this process, the final structure must be extruded from the sand. Workers use shovels to remove the excess sand and reveal the final product. The magnesium oxide mixed in with the sand causes the sand to become an active participant in the reaction, resulting in a mineral-like material with a microcrystalline structure. Compared to concrete, which has low resistance to tension and, as a result, needs iron reinforcement, D-Shape's structures have relatively high tension resistance and do not need iron reinforcement. The entire building process is reported to take a quarter of the time and a third to a half of the cost of building the same structure with traditional means using Portland cement, the material currently used in building construction.

Awards and achievements

NYC Waterfront Construction Competition

In the fall of 2012, D-Shape entered into the NYC Waterfront Construction Competition hosted by the New York City Economic Development Corporation (NYCEDC) in which competitors had to create a solution to help strengthen New York City's deteriorating piers and coastline structures. D-Shape's idea called, "Digital Concrete," was to take 3-D scans of each piece of pier or infrastructure and then print a support jacket for each specific piece. D-Shape was the First Place Winner and received $50,000 for the idea, which is estimated to save New York City $2.9 billion.

Radiolaria

D-Shape created the tallest 3-D printed sculpture, Radiolaria, in 2009. The sculpture was created by Italian architect Andrea Morgante and inspired by radiolarians, unicellular organisms with intricate mineral skeletons. The current version of the sculpture is only a 3 x 3 x 3 m scale model of the full-size Radiolaria that is planned to be put in a roundabout in Pontedera, Italy.

Future of D-Shape

Currently, Jake Wake-Walker and Marc Webb are working on a documentary titled The Man Who Prints Houses, about Enrico Dini and his invention.

D-Shape is still in development. It has printed a trullo, but the printer needs modifications in order to print larger structures.

Lunar bases

Brick made of agglomerated dust similar to lunar regolith, made for ESA by the Italian company D-Shape. Such bricks could cover a European permanent Moon base to protect it from radiations and meteorites. On display at Cité de l'Espace, Toulouse, France.

Because of D-Shape's capabilities, the European Space Agency (ESA) has taken interest in using the printer to build Moon bases using lunar regolith. D-Shape has been successful in printing components for the lunar bases with a simulated regolith, and has tested to see how the printer will work in the environment on the Moon.

References

  1. "Discovery Channel Covers DShape 3D Printing". Youtube, DShape3DPrinting. Retrieved 21 October 2013.
  2. Cesaretti, Giovanni; Enrico Dini; Xavier de Kestelier; Valentina Colla; Laurent Pambaguian (January 2014). "Building components for an outpost on the Lunar soil by means of a novel 3D printing technology". Acta Astronautica. 93: 430–450. Bibcode:2014AcAau..93..430C. doi:10.1016/j.actaastro.2013.07.034.
  3. Dini, Enrico. "Method and device for building automatically conglomerate structures CA 2602071 A1". US Patents. Retrieved 11 November 2013.
  4. Dini, Enrico. "Method for automatically producing a conglomerate structure and apparatus therefor US 8337736 B2". US Patents. Retrieved 11 November 2013.
  5. Cesaretti, Giovanni; Enrico Dini; Xavier de Kestelier; Valentina Colla; Laurent Pambaguian (January 2014). "Building components for an outpost on the Lunar soil by means of a novel 3D printing technology". Acta Astronautica. 93: 430–450. Bibcode:2014AcAau..93..430C. doi:10.1016/j.actaastro.2013.07.034.
  6. Cesaretti, Giovanni; Enrico Dini; Xavier de Kestelier; Valentina Colla; Laurent Pambaguian (January 2014). "Building components for an outpost on the Lunar soil by means of a novel 3D printing technology". Acta Astronautica. 93: 430–450. Bibcode:2014AcAau..93..430C. doi:10.1016/j.actaastro.2013.07.034.
  7. Edwards, Lin (19 April 2010). "3D printer could build moon bases". Phys.org. Retrieved 21 October 2013.
  8. Cesaretti, Giovanni; Enrico Dini; Xavier de Kestelier; Valentina Colla; Laurent Pambaguian (January 2014). "Building components for an outpost on the Lunar soil by means of a novel 3D printing technology". Acta Astronautica. 93: 430–450. Bibcode:2014AcAau..93..430C. doi:10.1016/j.actaastro.2013.07.034.
  9. Dini, Enrico. "Method for automatically producing a conglomerate structure and apparatus therefor US 8337736 B2". US Patents. Retrieved 11 November 2013.
  10. Parsons, Sarah (17 March 2010). "3-D Printer Creates Entire Buildings From Solid Rock". Habitat. Retrieved 22 October 2013.
  11. Belezina, Jan (24 February 2012). "D-Shape 3D printer can print full-sized houses". Gizmag. Retrieved 21 October 2013.
  12. "D-Shape Promises To Modernize New York's Shoreline Using 3D-Printing Technology". The Huffington Post. 3 June 2013. Retrieved 21 October 2013.
  13. "D-Shape wins top prize in NYC Waterfront Construction Competition". 3ders.org. 12 April 2013. Archived from the original on 13 October 2013. Retrieved 20 October 2013.
  14. Quirk, Vanessa (12 July 2012). "How 3D Printing Will Change Our World". Arch Daily. Retrieved 20 October 2013.
  15. Edwards, Lin (19 April 2010). "3D printer could build moon bases". Phys.org. Retrieved 21 October 2013.
  16. Blagdon, Jeff (21 February 2012). "British company uses 3D printing to make stone buildings out of sand". The Verge. Retrieved 21 October 2013.
  17. Quirk, Vanessa (12 July 2012). "How 3D Printing Will Change Our World". Arch Daily. Retrieved 20 October 2013.
  18. Edwards, Lin (19 April 2010). "3D printer could build moon bases". Phys.org. Retrieved 21 October 2013.
  19. Cesaretti, Giovanni; Enrico Dini; Xavier de Kestelier; Valentina Colla; Laurent Pambaguian (January 2014). "Building components for an outpost on the Lunar soil by means of a novel 3D printing technology". Acta Astronautica. 93: 430–450. Bibcode:2014AcAau..93..430C. doi:10.1016/j.actaastro.2013.07.034.

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