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Zhang, Ketao; Chermprayong, Pisak; Xiao, Feng; Tzoumanikas, Dimos; Dams, Barrie; Kay, Sebastian; Kocer, Basaran Bahadir; Burns, Alec; Orr, Lachlan; Alhinai, Talib; Choi, Christopher; Darekar, Durgesh Dattatray; Li, Wenbin; Hirschmann, Steven; Soana, Valentina; Ngah, Shamsiah Awang; Grillot, Clément; Sareh, Sina; Choubey, Ashutosh; Margheri, Laura; Pawar, Vijay M; Ball, Richard J; Williams, Chris; Shepherd, Paul; Leutenegger, Stefan; Stuart-Smith, Robert; Kovac, Mirko
Nature, 09/2022, Volume: 609, Issue: 7928Journal Article
Additive manufacturing methods using static and mobile robots are being developed for both on-site construction and off-site prefabrication . Here we introduce a method of additive manufacturing, referred to as aerial additive manufacturing (Aerial-AM), that utilizes a team of aerial robots inspired by natural builders such as wasps who use collective building methods . We present a scalable multi-robot three-dimensional (3D) printing and path-planning framework that enables robot tasks and population size to be adapted to variations in print geometry throughout a building mission. The multi-robot manufacturing framework allows for autonomous three-dimensional printing under human supervision, real-time assessment of printed geometry and robot behavioural adaptation. To validate autonomous Aerial-AM based on the framework, we develop BuilDrones for depositing materials during flight and ScanDrones for measuring the print quality, and integrate a generic real-time model-predictive-control scheme with the Aerial-AM robots. In addition, we integrate a dynamically self-aligning delta manipulator with the BuilDrone to further improve the manufacturing accuracy to five millimetres for printing geometry with precise trajectory requirements, and develop four cementitious-polymeric composite mixtures suitable for continuous material deposition. We demonstrate proof-of-concept prints including a cylinder 2.05 metres high consisting of 72 layers of a rapid-curing insulation foam material and a cylinder 0.18 metres high consisting of 28 layers of structural pseudoplastic cementitious material, a light-trail virtual print of a dome-like geometry, and multi-robot simulations. Aerial-AM allows manufacturing in-flight and offers future possibilities for building in unbounded, at-height or hard-to-access locations.
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