Pioneering Sustainable Construction with Robotic Additive Manufacturing: AUC’s Innovative Approach
In a groundbreaking initiative that marries cutting-edge technology with sustainability, two professors from The American University in Cairo (AUC) have devised an inventive construction system using Robotic Additive Manufacturing (AM). This novel approach, developed by Hanadi Salem and Sherif Abdelmohsen, redefines eco-friendliness and durability within the construction realm.
The Pioneers
Hanadi Salem, a leading figure in AUC’s Mechanical Engineering Department and director of the Additive Manufacturing Centennial Lab (AMCL), joined forces with Sherif Abdelmohsen, chair of AUC’s Architecture Department and director of the Robotic Fabrication Lab (RFL). Together, they conceptualised a construction system that leverages Robotic AM, utilising both metal and clay-based materials as primary construction components.
Robotic Additive Manufacturing
Robotic AM, a cutting-edge technology, employs movable robotic arms to manipulate metallic wires directly on the construction site. The innovation lies in its ability to significantly reduce energy consumption and nearly eliminate CO2 emissions compared to conventional building processes.
The system developed at AUC’s AMCL, the first of its kind in the Middle East, embraces the progressive concept of robotic deposition of construction materials. This not only leads to reduced energy usage and carbon emissions but also paves the way for erecting intricate and complex structures.
A High Potential Method
The system developed at AUC’s AMCL, the first of its kind in the Middle East, embraces the progressive concept of robotic deposition of construction materials. This not only leads to reduced energy usage and carbon emissions but also paves the way for erecting intricate and complex structures.
Salem highlights the ability of AM to generate high-value products with minimal waste, coupled with rapid production rates and reduced costs. This process enables innovative designs with shorter lead times. By amalgamating clay and metal through robotic-controlled AM, a significant reduction in carbon emissions and energy consumption is achieved, promoting a cleaner environment. Impressively, metal AM cuts energy usage by 45% and carbon emissions by a staggering 95%.
The application of robotically controlled metal AM holds immense potential in revolutionising construction and architectural practices. This technology is gaining traction in building towers, bridges, tunnels, intricate architectural designs, and even on-site construction.
Tailor-made applications
While clay has a historical significance in construction, the red fire clay utilised at AUC’s RFL presents a notable advancement. This clay exhibits exceptional strength, and resilience against higher temperatures and pressures, making it well-suited for high-performance applications. Abdelmohsen underscores its composition, comprising kaolin, feldspar, and quartz, which sets it apart from conventional clay bricks used in Egypt.
Unique clay bricks, crafted at AUC’s RFL, offer a new realm of possibilities in the construction industry. 3D printing with robots enables the creation of custom bricks tailored to specific design requirements. This process is not only more efficient than traditional moulding and firing but also yields less waste. Furthermore, it empowers precise control over production, guaranteeing consistent quality, strength, and durability.
Sustainably oriented
Embracing locally available resources, such as clay-based materials, instead of conventional bricks, holds the promise of precision and accuracy in implementing the latest technology. Abdelmohsen envisions integrating robotically controlled additive manufacturing into Egypt’s construction sector to enhance housing and infrastructure accessibility for a wider population. This transformation could stimulate job creation, efficiency gains, and innovative breakthroughs.
Salem emphasises the broader societal impact of AM, particularly among small and medium enterprises. The technology complements, rather than replaces, traditional manufacturing methods, offering the freedom to design, inspire innovation, and positively impact the environment. By shortening the product development cycle and fostering in-house concept development, AM can lead to reduced outsourcing and a competitive edge.
The innovative work of Salem and Abdelmohsen was displayed at AUC’s pavilion during COP27’s Green Zone, underscoring the university’s multifaceted commitment to climate change and sustainability. Through their pioneering efforts, AUC is not only transforming construction methods but also contributing to a greener, more accessible, and progressive future.
Learn More on Firstplanit
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