VISVESVARAYA TECHNOLOGICAL UNIVERSITY

BELAGAVI

Technical seminar Report on

“CONTOUR CRAFTING”
Submitted by

MEGHANA S S 4BB17CV009
In partial fulfilment of the requirement for the award of the
Bachelor Degree
in
Civil Engineering
Under the Guidance of
Mr. C R Shivakumar B.E., M. Tech
Assistant Professor
Department of Civil Engineering

DEPARTMENT OF CIVIL ENGINEERING

Bahubali College of Engineering
Shravanabelagola-573 135
2020-21
 BAHUBALI COLLEGE OF ENGINEERING

Shravanabelagola-573135

______________________________________________________
DEPARTMENT OF MECHANICAL ENGINEERING
CERTIFICATE

This is to certify that Ms. Meghana S S (4BB17CV009) has successfully

completed Technical Seminar in partial fulfillment of VIII Semester to award
the Bachelor Degree in Civil Engineering of the Visvesvaraya Technological
University, Belagavi during the year 2020-21. The Internship Report has been
approved as it satisfies the academic requirements in respect of Internship
prescribed for the Bachelor of Engineering Degree.

Mr. C R Shivakumar Mr. Avinash G B Dr. Gomatesh M. Ravanavar

Asst. Prof. & Guide Asst. Prof. & HOD Principal

Examiners

S. No. Name Signature Date

1.

2.
 ACKNOWLEDGEMENT
Apart from my effort, the success of this technical seminar work depends largely on the
encouragement and guidelines of many. I take this opportunity to express my gratitude
to the people who have been instrumental in the successful completion of this technical
seminar.

I express immense gratitude to my guide Mr. C R Shivakumar Assistant Professor,

Department of Civil Engineering, BCE, Shravanabelagola for having extended his
priceless technical expertise. I also thank him for his patient thoughtful guidance and
also for his most generous support and encouragement towards the development of the
technical seminar.
I also express immense gratitude to technical seminar Co-ordinator Mr. RAKESH B J
Assistant Professor, Department of Civil Engineering, BCE, Shravanabelagola for his
encouragement and support for carrying the technical seminar.

I express my sincere thanks to Mr. Avinash G B Assistant Professor and Head of

Department of Civil Engineering, BCE, Shravanabelagola for his valuable
encouragement and support in carrying out the technical seminar by providing all the
facilities.

I also convey my sincere thanks and gratitude to Dr. Gomatesh M. Ravanavar,

Principal, BCE, Shravanabelagola for his kind encouragement.

I would like to thank my Parents and Friends for their constant encouragement in
carrying out the technical seminar work.

MEGHANA S S
(4BB17CV009)
 TABLE OF CONTENTS

CHAPTER TITLE PAGE

NO. NO.
CERTIFICATE

ACKNOWLEDGEMENT

ABSTRACT

1 INTRODUCTION 1

2 CONTOUR CRAFTING 3

2.1 CONTOUR CRAFTING TECHNOLOGY 4

2.2 INTEGRATED CONTOUR CRAFTING SYSTEM 6

3 CONTOUR CRAFTING PROCESS 7

4 APPLICATIONS OF CONTOUR 9

4.1 APPLICATIONS IN CONSTRUCTION 9

4.1.1 AUTOMATED REINFORCEMENT 11

4.1.2 AUTOMATED TILING OF FLOORS AND WALLS 12

4.1.3 AUTOMATED PLUMBING 13

4.1.4 AUTOMATED ELECTRICAL AND COMMUNICATION 14

LINE WIRING
4.1.5 AUTOMATED PAINTING 15

4.2 COMMERCIAL APPLICATION 16

4.3 LOW INCOME HOUSING 16

4.4 EMERGENCY HOUSING 17

4.5 SPACE COLONIES 17

4.5.1 ROBOTIC OPERATIONS FOR LUNAR 18-19
CONSTRUCTIONS
5 CASE STUDY 20

INFERENCE 21

REFERENCE 22
 ABSTRACT
As we already know the world population has now exceeded the 7 billion mark, and if the
prognosis of the United Nations comes true, there will be 9.2 billion people in 2050. As
the case is today, most of the people will want to live in the megacities because they
promise a better life and wealth. Due to this, the population density in the cities would
increase like never before. This would lead to redevelopment and slum rehabilitation
projects to be undertaken on large scale. Imagine a situation wherein a huge bunch of
people will need an urgent space to live in. Thus, a situation will arise whence the cities
will have to grow rapidly but also sustainably, keeping in mind the environmental effects
and also the economy. Contour Crafting is an emerging technology that uses robotics to
construct free form structures by repeatedly laying down layers of material such as
concrete. This has a great potential in automated construction of whole structures as well
as sub-components. Using this process, a single house or a colony of houses, each with
possibly a different design, may be automatically constructed in a single run. Tool path
planning and optimization benefits the technology by increasing the efficiency of
construction of complicated structures. This research has intended to provide a systematic
solution for improving the overall system efficiency and realizing the automation of the
CC technology for building custom-designed houses. CC can automatically construct
custom-designed structures by repeatedly laying down construction material. CC has the
capability to fabricate with thick layers using various materials and without compromising
surface quality unlike other automation methods.
CONTOUR CRAFTING

CHAPTER 1

INTRODUCTION

Since the early years of 20 th century automation has grown and prevailed in almost all production
domains other than construction of civil structures. Implementation of automation in the construction
field has been slow due to : a) Unsuitability of available automated fabrication technologies for large
scale products b) Conventional design approaches that are not suitable for automation c) Significantly
smaller ratio of production quantity/ type of final products as compared with other industries d)
Limitations in the materials that could be employed by an automated system e) Economic
unattractiveness of expensive automated equipment.

Current construction industry still remains labour intense and craft oriented industry. It causes several
problems in the areas of productivity, quality, safety and skilled labour shortages. In order to overcome
these issues, various types of automation and robotics technologies have been proposed and
implemented. Automation of various parts and products has evolved in the last two centuries. The
various conventional methods of manufacturing automation do not lend themselves to construction of
large structural members. A promising new automation approach is layered fabrication, known as rapid
prototyping. The current layered fabrication methods are limited by their ability to deliver a wide
variety of materials to the construction.

Currently Contour Crafting (CC) seems to be one of the layered fabrication technologies that is
applicable to construction of large structures such as houses. The construction automation will require
a paradigm shift in process technology. The Contour Crafting construction process fits in this category
and has the potential to revolutionize the industry, changing it from the conventional “cast-in-place”
paradigm to a layer by layer approach.

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CHAPTER 2
CONTOUR CRAFTING

Contour Crafting is a building printing technology being researched by Behrokh Khoshnevis of the
University of Southern California’s Information Science Institute. Khoshnevis stated in 2010 that
NASA was evaluating Contour Crafting for its application in the construction of bases on Mars and
Moon. After three years, in 2013, NASA funded a small study at the University of Southern California
to further develop the Contour Crafting 3D printing technique.

Contour Crafting is an additive fabrication technology that uses computer control to exploit the
superior surface-forming capability of trowelling to create smooth and accurate planner and free-form
surfaces. The key feature of Contour Crafting is the use of two trowels, which in effect act as two solid
planer surfaces, to create surfaces on the object being fabricated that are smooth and accurate. The
craftsmen have effectively used simple tools such as blades, trowels, putty knives with one or two
planer surfaces for forming materials in past form since ancient times. Surface shaping knives are used
today for industrial model making.

In CC, computer control is used to take advantage of the superior surface forming capability of
trowelling to create smooth and free-form surfaces. The layering approach enables the creation of
various surface shapes. It is a hybrid method that combines an extrusion process for forming the object
surfaces and injection process to build the object core.

Fig 2.1 Simple Historical Construction Tools

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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
nonorthogonal surfaces. The extrusion process builds only the outside edges of each layer. After
completion of extrusion each closed section of a given layer, if needed filler materials such as concrete
can be fill in the area defined by the extruded rims.

Fig 2.2 Contour Crafting Process

2.1 CONTOUR CRAFTING TECHNOLOGY

Extensive experiments have been conducted to configure the CC process to produce a variety of small
and full scale object. Small 2.5D and 3D parts with square, convex and concave features have been
fabricated from a variety of thermoplastic and ceramics materials. A limited axis but larger machine
was then developed to demonstrate the possibility of fabricating full scale concrete structures. Standard
houses can be built by integrating the CC machine with a support beam picking and positioning arm
to place beams for roofs. The structure can be built without external support elements using shape
features such as domes and vaults. The operation of CC machine for building a house can be light
weight and easy to transport and quickly assemble and disassemble by small crew. The operation may
be fully automated requiring minimum supervision.

In CC, computer control is used to take advantage of the superior surface forming capability of
trowelling to create smooth and accurate planar and free-form surfaces. The layering approach enables
the creation of various surface shapes using fewer different trowelling tools

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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 to build the object core.

Fig 2.3 Application of CC in House Construction

Fig 2.4 Structures Built By Contour Crafting

Some interesting aspects of this automated construction concept include:

 Maximum flexibility for architectural design allowing custom designs to be fabricated directly from
computer model of the building.
 Possibility for automatic imbedding of plumbing, electrical and communication networks.
 Dramatic impact on cost and speed (a 200 m2 , two- story house may be built within two days).
 Simplicity of construction logistics and management.
 Friendliness to the environment due to low emissions and waste less operation.
 Significantly reduced energy usage compared to manual construction.

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2.2 Integrated Contour Crafting System

An integrated CC system includes a control module, a geometry analysis module, a planning and
optimization module and a presentation module. The control module is a digital control of the Contour
Crafting machine. The geometry analysis having structure feasibility analysis and support structure
generation to annotate the original geometry. The planning and optimization module includes tool path
planning, multi-nozzle coordination and other operational issues. 3D presentation and real time
simulation functions are included in the presentation module. The machine task sequences are fed to
the Contour Crafting machine for construction execution after process planning, optimization and
simulation.

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CHAPTER 3

CONTOUR CRAFTING PROCESS

The CC process is based on an extrusion and filling process the extrusion process forms the smooth
object surface by constraining the extruded flow in the vertical and horizontal directions by trowels.
The orientation of the side-trowel is dynamically changed for better surface fit.

The side-trowel allow thicker material deposition while maintaining high surface finish. Thicker
material deposition cuts down manufacturing time. It is essential for building large-scale parts using
the additive process. The maximum deposition of layer thickness is limited to the trowel height.

As the extrusion nozzle moves according to the predefined material deposition path of each layer (rims)
are first created. The trowelled outer surface of each layer determines the surface finish quality of the
object. The top surface of each layer is also important for building a strong bond with the next layer.
The boundaries of each layer are created the filling process begins and material is injected to fill the
internal volume.

Fig 3.1 Multiple Nozzle and Single Nozzle Assemblies

The basic idea is that the extruder goes around the building’s margins to construct the walls. When one
layer is over it automatically moves up to build the next layer. It will be done slice by slice until it
reaches the desired height. Other materials like roofs, pipes and window frames will be placed by
another robot on the gantry. It will simply pick up the materials and

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place them on the right time. In the case of glass windows still need human labour because of its
fragility.

There are two key parts that make Contour Crafting superior to any other layered fabrication
technology. The two trowel create buildings with remarkable smooth surfaces while eliminating any
trace of the layers. Depending on the shape and the angle between the trowels, various designs can be
built. The quality of construction is much superior and flexible in making any kind of building.

To create a building with Contour Crafting, engineers or architects must design the buildings in CAD.
Then the design are analysed and verified by civil engineers, and should pass all the governmental
regulations. The materials for construction may differ according to the characteristics of the terrain,
cost-effective supplies of the materials and type of the structure.

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CHAPTER 4

APPLICATIONS OF CONTOUR CRAFTING

Contour Crafting technology is relatively straight forward and simple. The significant benefits of
Contour Crafting are short construction times, no human workers, cheaper cost and flexible of
materials. These characteristics gave researches several brilliant applications.

 Application in construction
 Commercial applications
 Low-income housing
 Emergency housing
 Space colonies

4.1 APPLICATIONS IN CONSTRUCTION

A single house or a colony of houses, 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.

Design flexibility: The process allows architects to design structures with functional and exotic
architect 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. The quantity of each material may be controlled by computer and correlated to various
regions of the geometry of the structure being built.

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Fig 4.1 Construction of Conventional Buildings Using CC

Utility conduits: Utility conduits are built into the walls of a building structure precisely as dictated
by the CAD data.

Fig 4.2 Complex Wall Section

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Fig 4.3 Construction of Adobe Buildings Using CC

Paint ready surfaces: The quality of surface finish in Contour Crafting is independent of the size of
the nozzle orifice. Sand, gravel, reinforcement fiber and other applicable materials available locally
are mixed and extruded through the CC nozzle. The surface quality in CC is such that no further surface
preparation would be needed for painting surfaces.

Smart materials: The deposition in CC is controlled by computer, accurate amount of selected

construction materials such as smart concrete may be deposited precisely in the intended locations.
Elements such as strain sensors, floor and wall heaters can be built into the structure in an integrated
manner.

4.1.1 AUTOMATED REINFORCEMENT

Robotic modular embedding of steel mesh reinforcement into each layer may be devised. The three
simple modular components may be delivered by an automated feeding system that deposits and
assembles them between the two rims of each layer of walls built by Contour Crafting. A 3D mesh can
be built for columns. The mesh will follow the geometry of the structure. It is possible to feed glass or

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carbon fiber tows through the CC nozzle to form continuous reinforcement consolidated with the
matrix materials to be deposited. Reinforcement can also be provided using the post-tensioning system.

(a)

(b)

Fig 4.4(a, b, c) Reinforcement Components and Assembly Procedure for Walls and Columns

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4.1.2 AUTOMATED TILING OF FLOORS AND WALLS

Automated tiling can be integrated by robotically delivering and spreading the material for adhesion
of tiles to floor or walls. Another arm can then pick the tiles from a sack and place it over the area
treated with the adhesive material.

(a)

(b)
Fig 5.5(a, b) Automated Tiling and Flooring

4.1.3 AUTOMATED PLUMBING

Contour Crafting based construction system has the potential to build utility conduits within the wall.
The automated construction of plumbing and electrical works are possible. For plumbing after
fabrication of several wall layers a segment of any type material pipe is attached through the

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constructed conduits into the lower segment already installed. The robotic system delivers the new
pipe segment and in case of copper pipes has heater element in the form of ring. The inside or outside
rim of each pipe segment is pretreated 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.

The needed components may be pre-arranged in a tray or magazine for easy pick up by the robotic
assembly system. Using this components various plumbing networks may be automatically imbedded
in the structure.

(a)

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(b)Fig 4.6(a, b) Plumbing Modules and Grippers

4.1.4 AUTOMATED ELECTRICAL AND COMMUNICATION LINE WIRING

A modular approach similar to industrial bus-bars may be used for automating electrical and
communication line wiring used in Contour Crafting. The modules have conductive segments of power
and communication lines imbedded in electrically non-conductive materials. All modules are capable
of being robotically fed and connected. The automated construction system could properly position
the outside access modules behind the corresponding openings on the wall.

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(a)

(b)

Fig 4.7(a, b) Electrical Modules and Assembly Process

4.1.5 AUTOMATED PAINTING

During layer wise construction of wall a spray painting robotic manipulator attached to the

CC main structure will paint each wall according to the specification. The painting mechanism may
be a spray nozzle or inject printer head.

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4.2 COMMERCIAL APPLICATION

The cost of construction includes huge amounts of material waste, labour problems and uneconomical
building design. Conventional construction is not eco-friendly, it produce air, water and noise
pollution. Hundreds of thousands of people injured or killed annually at construction field. Contour
Crafting make robots do the risky work preventing any kind of human injuries. It has lessen the harmful
impacts. Since materials will be precisely measured prior to construction, there will be no material
waste. It will produce less pollution than the conventional method. In the end when the people use CC,
the commercial industry will not be restricted by inefficient costs and human labor.

4.3 LOW-INCOME HOUSING

The population is growing faster than ever. Population in developing countries re 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 accommodate all of
poor citizens. The cheap and rapid characteristics of CC provides 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.

Fig 4.8 Slum in India

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4.4 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.

4.5 SPACE COLONIES

Contour Crafting is the best solution for any extraterrestrial construction that NASA approved. 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 labor
power and time to construct building by themselves. Sending construction materials from earth is too
expensive and inefficient to carry out. By using lunar Contour Crafting, there is no need for human
labor.

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.

Understanding of the following is crucial for successful planetary construction


The fluid dynamics and heat transfer characteristics of the extrudate under partial gravity level

Process such as curing of the material under lunar environmental conditions

Structural properties of the end products as a function of gravity level

Effects of extrudate material composition on the mechanical properties of the constructed structure.

One of the ultimate goals of the Human Exploration and Development of Space (HEDS) program of
NASA in colonization, building habitats for long term occupancy by humans. The proposed approach
has direct application to NASA’s mission of exploration, with the ultimate goal of in- situ resource
utilization for automated construction of habitats in non-terrestrial environments.

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The ability to construct support-less structures is an ideal feature for building structures using in-situ
materials. To explore the applicability of the CC technology for building habitats on the Moon and
Mars. In the recent years there has been growing interest in the idea of using these planets as platforms
for solar power generation, science, industrialization, exploration of our solar system and beyond and
for human colonization. The moon has been suggested as the ideal location for solar power generation
and subsequent microwave transmission to earth via satellite relay stations.

Fig 5.9 Lunar Contour Crafting

4.5.1 ROBOTIC OPERATIONS FOR LUNAR CONSTRUCTION

CC technology requires accurate, variable speed motion control of the nozzle over the entire
construction work volume. It is best to make the gantry frame mobile in order to eliminate on-site
human assembly and disassembly. The mobile gantry robot should be capable or retractable for launch
and deployment at the lunar construction site.

OPERATION


Launch the mobile gantry robot with gantry collapsed or retracted.


After landing traverse to the construction site with the gantry still retracted.


Upon arrival to the construction site deploy the gantry.

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
Perform self- alignment and leveling of the gantry


Ensure that the nozzle, hopper, and material delivery system operate properly.


Perform contour crafting construction


After the completion of the construction, retract the gantry into transport configuration


Traverse to a new construction site for the next construction.

A lunar mobile gantry robot can be viewed as a two rower platform connected by a cross beam. Passive
complaint joints and position sensors can be utilized for safe and reliable mobility control. The mobile
platform having 4 wheels with steering and drive motors each wheel. The mobile gantry robot requires
as many as seven retractable beams for lunar launch and deployment- four horizontal beams, two
vertical posts, and one top crossbeam. The mobile gantry robot will have passive compliant joints
during the traverse, deployment and retraction operations to allow flexing of the structure to reduce
stress on the components. These joints will have to be locked after the alignment, levelling and
calibration operation.

(a) Launched

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CHAPTER 5
CASE STUDY OF CONTOUR CRAFTING

 Contour Crafting simulation plan for Lunar Settlement infrastructure build-

up
NIAC Phase-I Final Project Report – October 2012 B. Khoshnevis, A. Carlson, N.
Leach and M. Thangavelu

Economically viable and reliable building systems and tool sets are being sought,
examined and tested for extraterrestrial infrastructure buildup. This project focused on
a unique architecture weaving the robotic building construction technology with designs
for assisting rapid buildup of initial operational capability Lunar and Martian bases. The
project aimed to study new methodologies to construct certain crucial infrastructure
elements in order to evaluate the merits, limitations and feasibility of adapting and using
such technologies for extraterrestrial application. Current extraterrestrial settlement
buildup philosophy holds that in order to minimize the materials needed to be flown in,
at great transportation costs, strategies that maximize the use of locally available
resources must be adopted. Tools and equipment flown as cargo from Earth are
proposed to build required infrastructure to support future missions and settlements on
the Moon and Mars.

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INFERENCE

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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REFERENCE

JOURNALS
1. Neil Leach, Anders Carlson, Behrokh Khoshnevis and Madhu Thangavelu. “Robotic
construction by contour crafting: The case of lunar construction.” International Journal of
Architectural computing 10, no.3(2012):423-438.

2. Khoshnevis, Behrokh, Dooil Hwang, Ke-Thia Yao, and Zhenghao yeh. “Megha-scale
fabrication by contour crafting.” International journal of Industrial and Systems Engineering
1,no.3(2006):301-320.

WEBSITES VISITED

1. https://www.researchgate.net

2. https://www.nasa.gov

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