3D printing is an additive technology that layers material over one another to form structures. This technique offers great design flexibility and can create intricate geometries that cannot be produced through conventional construction methods.
An initial virtual design is created and acts as the blueprint for the printer to read, then notches are cut in each log so they will fit over each other perfectly.
Designing
Many people dream of living in a log cabin, yet its cost often makes this type of dwelling out of reach. Thanks to modern construction techniques and advances, however, owning one may soon become reality for more people than ever before.
3D printing is a relatively recent technology that uses computer-aided design (CAD) files to produce three-dimensional physical objects. While still relatively young compared to other industries, its disruption in manufacturing and logistics industries has already caused massive change.
3D printing first became mainstream during industrial machines’ manufacture and tool maintenance. Since then, its technology has expanded exponentially; makers and hobbyists now often utilize it to design their own creations and build things with them; schools use 3D printing technology for hands-on learning with students.
Log cabins were popular architectural structures in Scandinavia, where straight pine and spruce tree trunks were easily available. Typically constructed without nails – though nailed together securely enough – notches in each log helped maintain stability for this style of building.
Mortar chinking (a mixture of clay, sand and animal saliva) was applied between logs for insulation and additional strength, providing insulation as well as strengthening. Although chinking is still used today in log homes, many builders now prefer faster and cleaner construction approaches using wood/plastic composite materials instead.
Printing
3D printing is a manufacturing technique that utilizes layering to build structures. This method is ideal for producing customized, complex products quickly. 3D printing also lends itself well to prototyping as designers can quickly produce models in different materials and finishes quickly. Furthermore, 3D printing reduces environmental waste as its use of much smaller amounts of material means lower production waste production rates than traditional production methods.
One of the primary challenges associated with 3D printing for construction is handling complex architectural models. Thanks to recent technological advancements, this is now achievable; using additive manufacturing techniques such as powder bonding and binder jetting, architects can now print structures of any size using additive printing technologies such as 3D printers.
Cornell University engineers recently constructed a two-story house using an impressive printer that mimics funnels to deliver concrete (KTRK, 2022). While impressive, this technology still poses several serious drawbacks.
First of all, 3D printing for construction can be expensive – printers used on this project cost over $49,000 each. Second of all, the process can be slow – at least three days must pass between printing one cubic foot of concrete and building two-story homes. Furthermore, skilled construction workers are scarce; therefore implementing this technology may prove more challenging.
Assembly
3D printing transforms virtual models into solid three-dimensional objects by depositing successive layers of material. It is used in numerous fields such as manufacturing, medicine, architecture and custom art design – manufacturing, medicine, architecture as well as custom art design being popular applications of 3D printing. Fused Filament Fabrication (FFF), the most prevalent 3D printer type used today by manufacturers and other institutions alike for 3D printing objects using thermoplastic filaments heated and extruded by heaters is one form of 3D printer while stereolithography (SLA), Selective Laser Sintering (SLS), polyjet printing Multi-Jet Fusion (MJF) Direct Metal Laser Sintering (DMLS).
Making physical objects starts with creating virtual designs using computer-aided design software, then breaking these down into layers so the 3D printer can build it layer by layer through a process known as slicing.
Lok and Zivkovic’s project is the result of two years of research and innovation. Their ultimate goal is to be able to print multifamily homes using this Houston house design as a pilot program – this model home being just a precursor.
The duo’s goal is to develop a new type of construction that does away with costly tooling, fixtures and assembly. Their goal is also to reduce labor costs while remaining more resilient against natural disasters – ultimately making printed log cabins cheaper and faster to construct than their traditional counterparts.
Finishing
3D printing has revolutionized how we work and live. The cutting-edge technology has found applications across industries from auto to aerospace to education to construction – but one project in particular has garnered widespread interest: 3D printed homes.
According to Grand View Research, futuristic buildings are growing at a rate of 23 percent compound annual growth. This new-age construction method could revolutionize how we build homes; its creators took several years and two dedicated people several months each to bring The Ashen Cabin into being.
Once wall framing is complete, carpenters install doors and windows to complete a weathertight shell – this stage is known as “rough-in,” typically completed by subcontractors who have obtained licenses to perform these services. Electrical, plumbing, HVAC systems may also be installed during this phase.
Log cabins require a system of structural elements to support their weight and secure the logs into position, typically comprised of 21/2-inch steel bars inserted through channels routed in their ends, covered by frames. Mortar chinking provides additional strength while helping maintain spacing between logs.
Zivkovic and Lok’s ultimate goal is to use their designs to quickly print multiple-family homes on demand, but first they must overcome some hurdles – such as labor shortages or higher building material costs than drywall. The Houston project is an important first step toward this end, though.