USC

CRAFT Center for Rapid Automated Fabrication Technologies

USC

Grand Challenge

Fundamental Research

Technology Thrusts

Extrudable Materialsand Fabrication

Integrated SoftwareSystems

Modular Componentsand Assembly

A House in a Day

Architectural Impact

Technology Demonstrations– Mega-Scale Layered Fabrication –

Industrial Parts& Molds

Freestanding ObjectsArchitecturalScale Models

ExtraterrestrialConstruction

Public Art

Environmental Impact Regulatory Impact

Employment Impact

Economic Impact

Mathematical Modelsof Fabrication Processes

4D Modelingand Visualization

Feasible GeometryReasoning

Freeform/Geometry

Composite Materials

Fluid Dynamics

Novel Structure Testing

Materials/Structures

Workflow & LogisticsPlanning

System PerformanceTesting and Evaluation

Multi-RobotCoordination

Collaborative Design

Systems/Processes

Dynamic Modelingand Control

Embedding Capabilitiesduring Fabrication

Real-Time Inspection

Sensing/Acting

Social Impact

USC

CRAFT - Vision and Goals

To develop the science and engineering needed for rapid automated fabrication of structures of various scales, up to very large objects such as buildings.

The goal is a major breakthrough in Mega-Scale fabrication.

USC

Grand Challenge

Building a custom-designed house in a day while radically reducing the costs, injuries, waste and environmental impact associated with traditional construction techniques.

affordable housing for the 30 million U.S. households facing cost burdens or overcrowding; emergency housing for the 37 million/year victims of natural (and/or man-made) disasters;new styles of housing based on curved rather than straight surfaces;extraterrestrial buildings constructed from in situ materials;

With national construction-related expenditures currently totaling close to $1 trillion annually, the potential impact is enormous.

The goal: a revolution in housing construction

USC

Grand Challenge – a house in a day

Architectural Impact

Environmental Impact

Regulatory Impact

Economic Impact

Social Impact

Employment Impact

USC Development PhasesG

ran

d C

ha

llen

geE

xtru

da

ble

Ma

teria

ls&

Fa

bric

atio

n

SingleResidence

SingleResidence

Multi-storyMulti-unit

Multi-storyMulti-unit

Community &

Infrastructure

Community &

Infrastructure

SimpleRoomSimpleRoom

Single-Materialnozzle/feed

Flat roofconstruction

Buildingsimple walls

Door/window withlintel/sacrificial support

Multi-materialnozzle assembly

Modular reinforcement/electrical/plumbing

Sensorembedding/testing

Supportlessroofs

Multi-crossBeam gantry

Community-scalelogistics planning

Structure testing & modeling: Whole structure testing

Process modeling

Control system: Basic Geometry Multi-robot Complex geometry

Visual alignment Surface quality inspection Video logging

Structural health monitoring

Intelligent CAD/CAM Structure feasibility Fabrication plan generation

Collaborative Assembly Reinforcement/Plumbing/Electrical

Logistic planning

Multi-materialsimple structures

Walls w/complexgeometry

Material engineering Composites & reinforcement Digital construction material

Single material delivery Multi-material delivery

Mo

du

lar

Co

mp

on

en

tsa

nd

As

se

mb

ly

Inte

gra

ted

So

ftwa

reS

ys

tem

s2005 2006 2008 2009 2010

USC

Grand Challenge

Fundamental Research

Technology Thrusts

Extrudable Materialsand Fabrication

Integrated SoftwareSystems

Modular Componentsand Assembly

A House in a Day

Architectural Impact

Technology Demonstrations– Mega-Scale Layered Fabrication –

Industrial Parts& Molds

Freestanding ObjectsArchitecturalScale Models

ExtraterrestrialConstruction

Public Art

Environmental Impact Regulatory Impact

Employment Impact

Economic Impact

Mathematical Modelsof Fabrication Processes

4D Modelingand Visualization

Feasible GeometryReasoning

Freeform/Geometry

Composite Materials

Fluid Dynamics

Novel Structure Testing

Materials/Structures

Workflow & LogisticsPlanning

System PerformanceTesting and Evaluation

Multi-RobotCoordination

Collaborative Design

Systems/Processes

Dynamic Modelingand Control

Embedding Capabilitiesduring Fabrication

Real-Time Inspection

Sensing/Acting

Social Impact

USC

Interrelationships among the three research thrusts

Integrated

Software

Systems

Modular

Components

& Assembly

Extrudable

Materials &

Fabrication

Architectural

Design

Logistics plan

Predictive

performance

Inspection plan

Sensory D

ata

Supply Dispatch

Indexed Video Log

Structure design &

Performance Requirements

Performance

Restrictions

Visual Data

CC

Hardware

Robot

Commands

Hardware

Feedback

Assembly plans

Nozzle path plan

USC

Extrudable materials & fabrication

• Perform underlying basic research necessary to develop the materials and structures for automated mega-scale fabrication

• Integrate materials into ultra-efficient structures

• Integrate materials with delivery systems and robots from other thrusts

USC

Robotics fab, modular components & assembly

• Perform research and develop various mono and distributed robots, tools, software and their integration into systems for assembling modules in situ to form functional attributes of structures

• Robots’ locations, movements and working areas are dynamically changing along with environment. Develop a mathematical / geometric model of environment and a robot coordination protocol.

• Perform the fundamental research in the modules to be placed internal to the extruded material that transform an extrusion into a functional wall or roof of a mega-scale structure. The modules that make a post-modern interactive structure include:

• normal reinforcing, plumbing, and electricity conduits • Integrated communication, interactive sensing and displays

• Integrate the Modules and Assembly Thrust with Extruded Materials and Software

USC

USC

Embedding IT components

USC

Automated Painting

USC

Dynamic Control

Material FlowComputation

Flow ControlLaw

Position Sensors

Nozzle ActuatorNozzle Control

Law

Robot WheelMotors

Flow Sensor

Position Sensor

GantryDynamic

Model

GantryDynamic

Model

Material FlowDynamics

Material FlowDynamics

SystemDynamics

DesiredMaterialFlow

NozzlePosition &Orientation

GantryPosition

WheelTorques

NozzleForces

CommandedPosition

MaterialFlow

+

-

+

-

Gantry MotionController

USC

Goals

• Perform the fundamental research and develop the software components for automating mega-scale fabrication

• Integrate components with each other and with robots from other thrusts

USC

USC

Industrial Sectors

• Materials• Construction• Equipment• Software • Architects• Real Estate• Other application sectors

USC

Industrial Membership

Industrial membership – 3 tiers– Senior Member - $100,000– Regular Member - $20,000 to $50,000– Technology Associate – small business

Benefits to Industry– Seat on CRAFT ERC industrial advisory board – Senior Member– Licensing (Senior Member – exclusive)– Focused research projects– Access to cutting edge research– Access to center facilities and expertise for R&D projects– Contact with graduate students– Industry-University exchange program– SBIR and STTR partnerships– Industry-University Company Day – Senior Member

USC

Expressions of Support

• Materials– Degussa Corporation (committed)– Maxit Group (committed)– CEMEX– Elotex– ECRA (European Cement Research Academy)– VDZ (German Concrete Research Academy)

• Equipment– Siemens– John Deere– Parker-Hannifan

USC

Expressions of Support

• Construction– Shea Homes– Parsons– Shimizu – Bechtel– Boeing (space)

• Government– NASA (committed)– U.S. Army

USC

Expressions of Support

• Architects– GL Forms (Greg Lynn)– Gehry Technologies – Cal-Earth

• Real Estate– ConAm (builds low income housing in

Mexico) – Regency Outdoor Advertising

USC

Management Plan

Executive Board:

Provost (USC)Vice Provost, Research (USC)

Dean of VSoE (USC)Director of ISI (USC)

Executive Board:

Provost (USC)Vice Provost, Research (USC)

Dean of VSoE (USC)Director of ISI (USC)

Scientific Advisory board

Industrial Advisory Board

Student Leadership Council

Scientific Advisory board

Industrial Advisory Board

Student Leadership Council

Education DirectorEducation Director Industrial Liaison Director

Industrial Liaison Director

Pre-College (K-12)Undergraduate & Graduate

OutreachCREST/LSAMP

EPICS/LINC/Fablabs

Pre-College (K-12)Undergraduate & Graduate

OutreachCREST/LSAMP

EPICS/LINC/Fablabs

Industry ParticipationFaculty Mini-SabbaticalTechnology TransferIntellectual Property

Industry ParticipationFaculty Mini-SabbaticalTechnology TransferIntellectual Property

Grand ChallengeTechnology Thrusts:Extrudable Materials & FabricationModular Components & AssemblyIntegrated Software Systems (Neches/Rosenbloom)

Grand ChallengeTechnology Thrusts:Extrudable Materials & FabricationModular Components & AssemblyIntegrated Software Systems (Neches/Rosenbloom)

ProvostProvost

KhoshnevisDirector

Rosenbloom Deputy Director

Joe SullivanAssociate Director

KhoshnevisDirector

Rosenbloom Deputy Director

Joe SullivanAssociate Director

Dean of EngineeringDean of Engineering

USC

Thank you

please visit

www.ContourCrafting.org