An intelligent extrusion system for additive manufacturing in construction

Additive manufacturing (AM), popularly known as ‘3D printing’, is a manufacturing technique that builds physical 3D objects layer by layer using materials such as polymers, metals, and composites. The widespread popularity of additive manufacturing in most industries ranging from biomedical to aerospace suggests a revolution in manufacturing which have recently emerged in the construction sector and large-scale printing due to its zero waste, design freedom and contribution towards a circular economy.

One of the main problems in current state of the art AM printers that they lack any sort of feedback to keep an eye on the process, thus, causing a lot of failed prints and weak structures. This research aims to develop an intelligent extrusion system that would allow us to 3D print recycled cementations materials, to reduce the amount of waste and better automate the construction process.

An intelligent adaptive nozzle for additive manufacturing in construction
An intelligent adaptive nozzle for additive manufacturing in construction

So far, a platform of a gantry system and various extrusion systems have been developed in house to 3D print sustainable concrete mixes. The final phase is to add monitoring system and train it to detect various errors that occur while printing. This will allow the system to adaptively correct any errors that might happen and ensure the perfect layer every time.  

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Meet the Principal Investigator(s) for the project

Mr Mohammad Rafiq Swash
Mr Mohammad Rafiq Swash - Dr Rafiq Swash is an academic, researcher and technology leader whose work sits at the intersection of artificial intelligence, autonomous systems, advanced 3D imaging and digital transformation. He joined Brunel University of London in 2013 and serves in the Department of Electronic and Computer Engineering and Digital Media, where he leads the Holoscopic 3D Research Group and previously served as Programme Director for the MSc in Digital Design and Branding. He holds a PhD in Holoscopic 3D Imaging, Processing and Display Systems and a First-Class BEng in Computer Systems Engineering, both from Brunel, where he was awarded the Chancellor's Prize and the Brunel Medal for Outstanding Achievement. He has since completed executive programmes at Saïd Business School, University of Oxford, and the University of Cambridge Institute for Sustainability Leadership. Dr Swash's research has spanned several major internationally funded projects, including the European Commission's RUSHES, 3DVIVANT and Internet of Radio Light programmes, and the Qatar National Research Fund's CEPROQHA initiative. He has authored more than seventy peer-reviewed publications and supervised 20+ doctoral researchers and 200+ PG/UG students to completion. He has also held a Visiting Professorship at the Chinese Academy of Sciences. Alongside his academic career, Dr Swash has built substantial entrepreneurial experience in translating advanced research into industrial applications, with a focus on AI-enabled autonomous systems for global industrial logistics. His ventures have delivered live commercial deployments across the world with several of the largest port operators, and he was shortlisted for the Great British Entrepreneur Awards in 2023. He currently serves on the Advisory Boards of the Freight Innovation Cluster at Connected Places Catapult and Marlan Space in Abu Dhabi. His work has been recognised through the Vice Chancellor's Doctoral Research Prize, the IEEE Broadcast Technology Society Best Paper Award, and selection among the Top 50 high-impact research outcomes in Brunel University's 50th anniversary celebrations. He serves on the editorial board of Frontiers in Virtual Reality, and is a Fellow of the Royal Society of Arts, a Fellow of Advance HE and a member of the Forbes Technology Council.
Mr Abdulrahman Albar

Partnering with confidence

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Project last modified 15/11/2023