Abstract:
The research and development focus on advanced strategies for large-format additive manufacturing (LFAM) using 3D printing, including the development of 3D printing equipment, such as multi-component extruders, high-flow filament printheads and pellet extruders. Emphasis is placed on optimizing control systems and process parameters to enhance accuracy, efficiency, and sustainability in large-scale 3D printing, with an additional focus on recycling waste thermoplastics.

Main objectives:

• To study advanced large-scale 3D printing strategies and process parameters to improve productivity, printability and accuracy.

• To develop large-scale 3D printing equipment up to TRL5 for various materials and material mixtures.

• To develop control systems for robotic additive manufacturing and designing of complex printable geometries

Research content:
This research is dedicated to advancing large-scale 3D printing by developing advanced manufacturing strategies and innovative technologies. The primary aim is to optimize 3D printing processes and parameters, significantly enhancing productivity and printability. Central to this effort is the development of customized 3D printing equipment capable of handling a wide range of materials and complex material mixtures, with the objective of achieving Technology Readiness Level 5 (TRL5).

A key focus area involves pioneering advanced 3D printing strategies, including non-planar, multi-planar, segmented, and spatial geometries. These approaches transcend traditional layer-by-layer techniques, allowing for the production of more complex and efficient structures. In parallel, multi-component extruders tailored specifically for 3D concrete printing (3DCP) are being developed, enabling precise deposition of multi-material components in large-scale structures. Additionally, high-flow filament printheads are being designed to substantially boost print speeds, making the production of large objects faster and more efficient.

Achievements include the remote operation of a robotic 3D printing cell at EXPO 2020 in Dubai, the world’s first 3D-printed concrete parkour playground, the first on-site 3D-printed architectural structure in Spain using locally sourced earthen materials, and significant contributions to multi-axis additive manufacturing strategies, which have been published in high-impact journals and professional periodicals.

Sustainability is a core aspect of this research, exemplified by the development of a large-scale pellet extruder engineered for processing waste thermoplastics. This technology not only facilitates the recycling of plastic waste into functional 3D-printed products but also advances a more circular economy in additive manufacturing. By integrating these advanced methods, the research aims to make large-scale 3D printing more efficient, versatile, and environmentally sustainable, setting the stage for its broader application across industries.

Publications:
KRČMA, Martin; PALOUŠEK, David; ŠKAROUPKA, David; BRAUMANN, Johannes a KOUTNÝ, Daniel. Method of Multiaxis Three-Dimensional Printing with Intralayer Height Variation for Stairstep Effect Compensation. Online. 3D Printing and Additive Manufacturing. 2023, roč. 10, č. 6, s. 1178-1189. ISSN 2329-7662. https://doi.org/10.1089/3dp.2022.0097

KRČMA, M.; ŠKAROUPKA, D.; VOSYNEK, P.; ZIKMUND, T.; KAISER, J.; PALOUŠEK, D. Use of polymer concrete for large-scale 3D printing. RAPID PROTOTYPING JOURNAL, 2021, no. 27, p. 465-474. ISSN: 1758-7670. https://doi.org/10.1108/RPJ-12-2019-0316

VESPALEC, A.; PODROUŽEK, J.; BOŠTÍK, J.; MIČA, L.; KOUTNÝ, D. Experimental study on time dependent behaviour of coarse aggregate concrete mixture for 3D construction printing. Construction and building materials, 2023, vol. 376, no. 5, p. 1-12. ISSN: 0950-0618. https://doi.org/10.1016/j.conbuildmat.2023.130999

Partners and Collaboration:
University for Arts and Design Linz, Hauptplatz 6, A-4020 Linz, Austria.

Association for Robots in Architecture, Kravoglstrasse 7/2, A-5020 Salzburg, Austria.

The Institute for Advanced Architecture of Catalonia, C/Pujades 102, 08005 Barcelona, Spain.

Profibaustoffe CZ, spol. s r.o., Vídeňská 140/113c, 619 00 Brno, Czech Republic.

VIA ALTA a.s., Nádražní 377, 675 21 Okříšky, Czech Republic.

Projects:
Robotic cell for hybrid manufacturing in Industry 4.0, Technology Agency of the Czech Republic (TA CR) – TREND industrial research and experimental development programme, FW09020130, 2023-2027.

Multicomponent compound and application technologies for 3D printing in construction,
Technology Agency of the Czech Republic (TA CR) – TREND industrial research and experimental development programme, FW06010034, 2023-2025.

Development of process parameters of additive manufacturing of highly filled waste thermoplastics, Technology Agency of the Czech Republic (TA CR) – ZÉTA applied research support programme, TJ01000354, 2018-2019.

Development of cement composites and process parameters for 3D printing of elements complying the requirements of traffic constructions, Technology Agency of the Czech Republic (TA CR) – 3th public competition of the Transport 2020+ program, CK03000240, 2022-2025.

Research and development of 3D printers for use in construction industry, Technology Agency of the Czech Republic (TA CR) – EPSILON applied research support programme, TH03010172, 2018-2021.

Contact person:
Ing. David Škaroupka, Ph.D.