1.

Abstract
This report deals with Contour Crafting, emphasizing its importance in
construction technology. 3D printing is evolving quite quickly, and new
technologies are unveiled regularly. Indeed, it is a real hotbed of
technological innovations. Additive manufacturing now has a lot of
applications and tends to go even further year after year. Contour Crafting, a
3D printing method specifically used in the construction sector, allowing to
print large constructions. Let‟s discover what is Contour Crafting, how it can
be used, and how it will revolutionize the construction sector.

2.Introduction
Abraham Maslow an American psychologist gave a theory on hierarchy of
needs for human needs in form of pyramid. Physiological needs such as
food, shelter marked the bottom of the pyramid. If these needs are not
satisfied the human body cannot function optimally. Maslow considered
physiological needs the most important as all the other needs become
secondary until these needs are met.
There is a problem of housing all over the world. Governments across the
world are looking towards solution in construction sector so that housing to
all can be provided at lower price in minimum possible time.
Conventional methods of construction has lots of problems –
1) Conventional method of construction is slow. It takes about 4-6 months to
build a normal house and for rural areas time taken is about 9 months.
Increased amount of time results in an increased spending of money on
the construction
2) Conventional method of construction depends largely on labour power.
Around 50% of total cost of construction goes on labour.
3) Construction sector is hazardous. In India there are about 40 deaths per
day of people associated with construction activities, making construction
sector a deadliest sector.
4) Conventional method of construction is wasteful and generates a lot of
carbon emission. A lot of concrete and other materials are wasted due to
their inefficient use and conservative nature of construction methods.
Also since energy sources used in the construction activities mainly
comes from non-renewable sources of energy, a lot of carbon emission
takes place. It is estimated that construction industry is responsible for
around 40% of all carbon emissions around the globe
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 5) Conventional methods of construction is corruption prone and is costly
and over budget. The construction market is huge – so huge that it is
estimated to be worth more than $ 3.2 trillion per year and make up for 2-
3% of developing countries‟ GDP and 5-7% of developed countries‟
GDP. The amount of losses through corruption range between 10 and
30%, which together with mismanagement and inefficiency makes up for
close to $6 trillion losses. These numbers highlight the size of the
problem and why eradicating corruption would make a big difference for
the industry and for the overall economy.

Contour crafting method of construction can be used to solve most of the

above problems in the construction sector.

3.CONTOUR CRAFTING

Contour Crafting (CC) is an additive fabrication technology that uses computer

control to exploit the superior surface-forming capability of troweling to create
smooth and accurate planar and free-form surfaces (Khoshnevis et al., 2001-a;
Khoshnevis et al, 2001-b, khoshnevis 2002). Some of the important advantages
of CC compared with other layered fabrication processes are better surface
quality, higher fabrication speed, and a wider choice of materials. The key
feature of CC is the use of two trowels, which in effect act as two solid planar
surfaces, to create surfaces on the object being fabricated that are exceptionally
smooth and accurate. Artists and craftsmen have effectively used simple tools
such as trowels, blades, sculpturing knives, and putty knives, shown in Figure 1,
with one or two planar surfaces for forming materials in paste form since
ancient times. Their versatility and effectiveness for fabricating complex free-
form as well as planar surfaces is evidenced by ancient ceramic containers and
sculptures with intricate or complex surface geometries as well as detailed
plaster work that have shapes as complicated as flowers, on the walls of rooms.
Surface shaping knives are used today for industrial model making (e.g., for
building clay models of car bodies). However, despite the progress in process
mechanization with computer numerical control and robotics, the method of
using these simple but powerful tools is still manual, and their use is limited to
model building and plaster work in construction. In CC, computer control is
used to take advantage of the superior surface forming capability of troweling to
create smooth and accurate, planar and free-form surfaces. The layering

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approach enables the creation of various surface shapes using fewer different
troweling tools than in traditional plaster handwork and sculpting. It is a hybrid
method that combines an extrusion process for forming the object surfaces and a
filling process (pouring or injection) to build the object core. As shown in
Figure 2, the extrusion nozzle has a top and a side trowel. As the material is
extruded, the traversal of the trowels creates smooth outer and top surfaces on
the layer. The side trowel can be deflected to create non-orthogonal surfaces.
The extrusion process builds only the outside edges (rims) of each layer of the
object. After complete extrusion of each closed section of a given layer, if
needed filler material such as concrete can be poured to fill the area defined by
the extruded rims.

Figure 1. Simple Historical Construction Tools

Figure 2. Contour Crafting Process

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4. APPLICATION IN CONSTRUCTION
A single house each with possibly a different design can be automatically
constructed in a single run using Contour Crating technology. Conventional
structures can be built by integrating the CC machine with a support beam
picking and positioning arm and adobe structures. It may be built without
external support elements using shape features. The process allows architects to
design structures with functional and exotic architect geometries that are
difficult to realize using the current manual construction practice. Various
materials for outside surfaces and as fillers between surfaces may be used in
CC. The quantity of each material may be controlled by computer and
correlated to various regions of the geometry of the structure being built.

5. Characteristics of Contour Crafting

 Design Flexibility

The process allows architects to design structures with functional and

exotic architectural geometries that are difficult to realize using the
current manual construction practice.

 Multiple Materials

Various materials for outside surfaces and as fillers between surfaces may
be used in CC. Also, multiple materials that chemically react with one
another may be fed through the CC nozzle system and mixed in the
nozzle barrel immediately before deposition. The quantity of each
material may be controlled by computer and correlated to various regions
of the geometry of the structure being built. This will make possible the
construction of structures that contain varying amounts of different
compounds in different regions.

 Paint-Ready Surfaces

The quality of surface finish in CC is controlled by the trowel surface and

is independent of the size of the nozzle orifice. Consequently, various
additives such as sand, gravel, reinforcement fiber, and other applicable
materials available locally may be mixed and extruded through the CC
nozzle. Regardless of the choice of materials, the surface quality in CC is
such that no further surface preparation would be needed for painting

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 surfaces. Indeed an automated painting system may be integrated with
CC.

 Automated painting

During or after layer wise construction of walls a spray painting robotics

manipulator, attached to the CC main structure may paint each wall
according to desired specifications. The painting mechanism may be a
spray nozzle, or an inkjet printer head (such as those used for printing
large billboards). The latter mechanism makes painting wall paper or
other desired patterns possible.

 Automated tiling of floors and walls

Automated tiling of floors and walls may be integrated by robotically

delivering and spreading the material for adhesion of tiles to floors or
walls, as shown in Figure 3. Another robotic arm can then pick the tiles
from a stack and accurately place them over the area treated with the
adhesive material. These robotic arms may be installed on the same
structure which moves the CC nozzle.

Figure 3. Automated Tiling

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  Automated Reinforcement

Robotic modular imbedding of steel mesh reinforcement into each layer

may be devised, as shown in Figure 4. The three simple modular
components shown in this figure may be delivered by an automated
feeding system that deposits and assembles them between the two rims of
each layer of walls built by CC. A three dimensional mesh may be
similarly built for columns. Concrete may then be poured after the rims of
the wall or column are built by CC. The mesh can follow the geometry of
the structure. Note that in this configuration the CC nozzle, the steel
reinforcement module feeder, and the concrete filler feeder could all be
on the same gantry system. Such a system can create shapes with smooth
outer surfaces and reinforced internal structure automatically and in one
setup. As an alternative to traditional metal reinforcement, other
advanced materials can be used, such as the fibre reinforced plastics
(FRP). Since the nozzle orifice in CC does not need to be very small, it is
possible to feed glass or carbon fibre tows through the CC nozzle to form
continuous reinforcement consolidated with the matrix materials to be
deposited. In the proposed study, deposition of the FRP reinforcement by
a parallel nozzle built into the CC nozzle assembly will also be
considered.

Figure 4. Reinforcement components and assembly procedures for walls and

columns

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 Automated plumbing

Because of its layer by layer fabrication method, a Contour Crafting

based construction system has the potential to build utility conduits
within walls. This makes automated construction of plumbing and
electrical networks possible. For plumbing, after fabrication of several
wall layers, a segment of copper (or other material) pipe is attached
through the constructed conduit onto the lower segment already installed.
The robotics system, delivers the new pipe segment and in case of copper
pipes has a heater element (shown in red) in the form of a ring. The inside
(or outside) rim of each pipe segment is pre-treated with a layer of solder.
The heater ring heats the connection area, melts the solder, and once the
alignment is made, bonds the two pipe segments. Other universal passive
(requiring no active opening or closing) robotic gripper and heater
mechanism designs used for various plumbing components are also
shown in Figure 5. The needed components may be prearranged in a tray
or magazine for easy pick up by the robotic assembly system. Using these
components various plumbing networks may be automatically imbedded
in the structure.

Figure 5. Plumbing modules & grippers

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 Automated electrical and communication line wiring

A modular approach similar to industrial bus-bars may be used for

automating electrical and communication line wiring in the course of
constructing the structure by Contour Crafting. The modules, as shown in
Figure 6, have conductive segments for power and communication lines
imbedded in electrically non-conductive materials such as a polymer, and
connect modularly, much like the case of plumbing. All modules are
capable of being robotically fed and connected. A simple robotics gripper
can perform the task of grabbing the component from a delivery tray or
magazine and connecting it to the specified component already installed.
The automated construction system could properly position the outside
access modules behind the corresponding openings on the walls, as
specified by the plan. The only manual part of the process is inserting
fixtures through wall openings into the automatically constructed
network.

Figure 6. Electrical modules and assembly process

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6. Applications of Contour Crafting

 Low income housing

The population is growing faster than ever. Population in developing

countries are growing five times faster than those of developed countries.
They do not have residence or money to afford such population boom.
Slums form because the country‟s rate of urbanization is too slow to
accommodate all of poor citizens. The cheap and rapid characteristics of
CC provide a solution since a fully functional house can be made in less
than one day. By using this technology developing countries will be able
to solve housing problems of the current and future population. Currently
of all the money expended on construction of around 20-25 % goes in
financing, 25-30% on materials and 45-55 % on labour cost. CC will
reduce the duration of project reducing the finance cost. Using CC much
efficient usage of materials would be possible thus reducing the amount
of materials which are used. Also the labour cost would be significantly
reduced using CC technology.

 Emergency housing

The people are prone to some kind of emergency due to war, natural
disasters or economic crisis. So many peoples are suffering from these
problems. So the best option for them is a home. The house should be
cost effective, good quality and proper facilities are there. The CC creates
a fully functional house including pumping and heating within a day.

 Space Colonies

Peoples are already using tremendous amounts of money on shipping

research machines from earth to another planet, they need to minimize the
cost on the actual construction. Astronauts do not have much labour
power and time to construct building by themselves. Sending construction
materials from earth is too expensive and inefficient to carryout. By using
lunar Contour Crafting, there is no need for human labour. Once solar
power is available, it should be possible to adapt the current contour
crafting technology to the lunar and other environments to use this power
to build various forms of infrastructure. The lunar regolith can be sintered
using microwave to produce construction materials. The CC system that
uses microwave power to turn the lunar regolith into lava paste and
extrude it through the nozzle to create various structures.

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7. Comparison

Conventional methods of construction costs more than that of a structure build

by contour crafting method. Contour crafting provides much more architectural
flexibility as compared to conventional methods. Structures can be build at
record time using Contour crafting as compared to conventional methods. Also
usage of contour crafting would result in significant reduction in carbon
emission as compared to conventional methods.

8. Conclusion

Contour Crafting is the only layered fabrication technology which is suitable for
large scale fabrication. It has the potential for immediate application in low
income housing and emergency shelter construction. The CC approach has
direct application to extra-terrestrial construction. Construction of luxury
structures with exotic architectural designs involving complex curves and other
geometries is another candidate application domain for CC. Lunar Contour
Crafting appears to be a viable methodology for construction of Lunar and
Martian habitats. The CC technology has the potential to revolutionize the
industry, changing it from conventional „beam and post‟ paradigm to a layer by
layer approach. In terms of the country-specific case studies, Saudi-Arabia
would be better suited than China adopt CC for use in affordable housing
projects. Construction machines built for CC may be fully electric and hence
emission free. Because of its accurate additive fabrication approach Contour
Crafting could result in little or no material waste. The CC method will be
capable of completing the construction of an entire house in a matter of few
hours instead of several months as commonly practiced. This speed of operation
results in efficiency of construction and management and hence favourable
impacts the transportation system and environment. CC is a huge step towards
the future. It is cheaper, faster, safer, and easier than any other method. It is a
powerful potential construction method of the future.

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9. References

 Behrokh Khoshnevis (2002), “ Automated construction by Contour

Crafting –Related Robotics and Information Technologies”, Journal of
Automation in construction: The best of ISAR 2002, Volume 13, Issue 1,
January 2004, page no.5-19
 Behrokh Khoshnevis et al. (2006),”Mega-scale fabrication by Contour
Crafting”, International Journal of Industrial and Systems Engineering,
Volume 1.
 David Weinstein et al. (2015), “Determining the applicability of 3D
concrete construction (Contour Crafting ) of low income houses in
selected countries”, Cornell Real Estate Review, Article 11, volume 13
 Dong Min Kim (2013), “Contour Crafting; a future method of building”,
Illumin Article, writing 340
 Dooil Hwag et al. (2005),”An innovative construction process-Contour
Crafting “; 22nd International Symposium and Robotics in construction.
 Website -
https://www.youtube.com/watch?v=JdbJP8Gxqog
http://civilenggseminar.blogspot.com/2016/06/contour-crafting.html

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