This document summarizes a research project on Contour Crafting, which uses 3D printers to print houses by modifying the mechanics of traditional 3D printers to work with materials like fiber glass and gypsum. The goals of Phase I were to smooth the sides and enable layering of printed materials. Current results found the best curing time, pH level, fiber glass percentage, and an adjustment to the printer header to print smoother sides. Phase II goals include printing 2D shapes, with the ultimate goal being able to 3D print full houses on an industrial scale.

1. Contour Crafting
Research Coordinator: Aref Vali
Research Advisor: Ted Lee
Research Student: Tiffany Cheng

2.  What is Contour Crafting?
 Research Purpose
 Summary of tasks
 Phase I goals
 Current Results
 Phase II goals – CHE 491
 Future applications
Overview

3.  Contour Crafting (CC) is a layered fabrication
technology that has great potential for automating
the construction process
 Using this process, single house or colony of houses
may be automatically constructed in a single run with
embedded electrical, plumbing, and air conditioning
Website: http://www.contourcrafting.org/
Simpler terms: Using 3D Printers to print houses
What is Contour Crafting?

4.  To modify the mechanics of traditional 3D printers to
work with fiber glass and gypsum
 To adjust the materials and material ratios which
includes plaster, fiber glass, dispersant, retarder…etc
to work with 3D printers
Research Purpose

5.  Daily tasks includes
1) Organize experiment table
2) Help prepare and mix materials
3) Record data, observation, results, and advise on
future suggestions
4) Conduct background literature review and create
summary sheets
5) Occasionally help order materials/material samples
from companies to try in lab
Summary of Tasks

6.  Smoothen the sides
 Be able to layer up
Phase I Goals

7.  Try different ratios of plaster to fiber glass
 Add dispersant to help mixing
 Add retarder to adjust curing time
 Try different temperature of water (room temp vs
cold water)
 Try materials from different companies
Methodology

8. Example of Daily Recording
Water
Plasticizer
Gypsum
Dispersant

9.  Best curing time is about 45-60 minutes, when under
pressure ~15 minutes
 Best pH is around 5-7
 Header was adjusted to be shorter to print smoother
sides
 Best fiber glass percentage is around 2-5%
Current Results/Findings

10. Current Results/Findings

11.  Be able to print 2D shapes – cylinder, stars, clovers
Phase II Goals – CHE 491

12.  Phase III goal is expand to larger, industrial-size scale
Future Applications

13. Questions/Comments?