Tuesday 15 March 2022

ON 3D PRINTING


Reports on the new wonders of 3D printing seem to appear daily.# While nearly everything, anything, from intricate parts for planes, to shoes, wheels, statuettes, and sundry gadgets, is used as an example of what this new technology can produce, it is the adoption of 3D printing in the construction of buildings that appears to be becoming a core issue of intrigue for everyone.* The report today noted that the houses of the future should be different from those of the past with new design languages with the purpose of “shifting the paradigm of homebuilding” - see: https://www.archdaily.com/977809/icon-completes-first-house-in-new-series-of-additive-construction-explorations. While this might appear to be a truism rather than a hopeful prediction, the idea seems to have arisen from the technique of using 3D printing in construction. The suggestion is that 3D printing will change how we think about building and buildings more than anything else. The danger is that 3D printing might distract us from important issues, as the optimistic fervour for new technologies can, as we have seen with CAD programmes.





There is some irony in this statement, as the ICON house that the report spoke about as an example of 3D printing, seemed much like others with the exception of the 3D printed walls that were curved in plan, and had the linear, layered texture that we have come to expect from 3D printed concrete. Having seen some of the remarkable objects that have been manufactured using this technique, one can understand how just about any form might be possible; it is truly a clever idea. One hopes that the process can be used to maximise all possible benefits rather than just impose quirky, technical differences. One must never forget the complex subtle matters that linger in the background of all aspects of architecture, both practical and theoretical.





One also hopes that the enthusiasm for this technique of fabrication does not blind one to basic good building principles. Surely the most fundamental matter in building is that the assembly might stand up; that there will be some structural integrity in the whole construction that can accommodate all the stresses that can be expected. This issue involves materials and detailing. Concrete is used with clever mixes to provide some reinforcing, and smart patterns are devised to create ribbed structural entities. The element has to hold itself together and up, and provide the support required of it. What other materials might be used? How might they perform?





The concern with this process is joints. With the concrete layered in a continuous bead of the required proportions, the wall is made up of a multitude of horizontal joints. Everyone knows, or should know, that joints in concrete can be its weakness. There is the matter of continuity: 3D printing can go on forever, creating an endless extruded layer length in whatever configuration might be required. One should always remember not only the matter of joints as being a potential weakness, but also the requirement for joints to manage construction schedules, and possible movements in elements of larger sizes. The 3D printed examples seen appear to be happy to create large pieces of structure as one element, to suit the 3D printer. While construction joints may not be necessary with the easy continuity of the mechanised extrusion, one has to ask about control joints - joints that control and manage movements in the structure. All structures move. The performance properties of materials should never be neglected.






Architecture is really all about joints - see: https://voussoirs.blogspot.com/2012/06/architecture-as-joints.html. Joints can be potential points of weakness if not detailed carefully, not only structurally, but also in providing the basic requirement of building – shelter: keeping the water out. Experience soon highlights the necessity of good, basic construction detailing if moisture is to be kept out. One wonders about the layered joints in the wall: are these waterproof? The concrete has just been extruded on top of itself, with no compaction. Is the concrete itself waterproof? Water can easily track through and along the weaknesses in materials.





One can always argue that claddings and coatings might be able to provide a sealing layer, but most 3D printed projects appear to delight in exposing the original, raw, textured concrete ooze created by the printer. How will this material / surface / form perform? Might it grow moss? Mould? How will it weather? Could it be porous? Might water find its way through the wall; around the wall; under the wall; along the wall? How is the wall sealed at the base? How is it sealed at the top?Traditional construction uses damp-proof courses and weep holes to stop rising damp. What does a 3D printed wall use? Then there are the doors and windows. How are the joints around these elements sealed? Traditional construction in walls provides cavities, flashings, and the continuity of special inner drainage details to ensure that water is kept outside, using cavity ties with drip points, water stops, and weather bars. Windows and doors use these or flashings around them on all extremities to ensure that the water is appropriately kept outside and drained away. How does a 3D printed wall manage this detail? Does it simply ignore the principles and apply the ‘historic’ solution of expanding foam to fill the gap and hold the door and window frame, and not worry about porosity of the adjacent surfaces? The foam detail is used in heritage work where windows are fitted into old stone walls. That moisture can pass through the stonework around this seal never appears to worry anyone.





The principles of good building have been developed over the centuries; the volumes of W.B.McKay’s Building Construction are a classic reference. We must not let any enthusiasm for 3D printing distract us from these matters of rigour with materials and construction. We can 3D print whatever we like, and photograph the process and the product for publication and praise, but how might the structure and its assembly perform over time? Our passion has to be managed carefully in the context of good building practice. Water will get in wherever it can. It is not going to keep away just because something has been 3D printed. Likewise, structures will move over time, in spite of the marvellous photographs of the completed build that reveal the lovely layers of ooze: there are many matters to be accommodated. Insulation, too, becomes critical when thermal shelter is needed; the problems of condensation and mould have to be avoided. These unwanted matters soon overcome any delight in the building process and the picturesque outcome.





Unless we attend to these basic building concerns, then we will find ourselves in a real mess, with wonderful structures that might prove to be uninhabitable. The recent floods in southeast Queensland only make one think carefully about water, materials, and structures; damp and mould. 3D printing is a technique, not a wonder solution to everything. We might hope for miracles, but dividing or walking on water is not something available to many; keeping it at bay requires rigorous, careful attention.





One has to ask about the integrity of the wall – is it structurally adequate; can one fix into this; onto this? how? - as well as worry about its waterproof qualities. The wall might appear structurally sound and complete, but appearances do not tell the full story. Recently, when purchasing seed from the nearby produce store, the conversation turned to the flooding of the store. The place did not appear to be in a low area. “What, you got flooded?” “Yeah mate. The water poured in through the single skin block walls of the warehouse.” We forget the principles of construction at our peril. Our enthusiasm for new technology must be contained, managed, and carefully reviewed with a questioning mind to ensure that we do not repeat the failures of the past in our eagerness to use this new wonder.




While 3D printing might indeed change the way we think about building and buildings, it should not change the way in which we manage the demands of construction, their necessities. Given the world's entrancement with spirited design – e,g., Gerhy; Hadid; et.al. - one has to be concerned that ‘willy-nilly’ outcomes are not promoted on the basis that ‘progress’ will solve every problem that arises in the future, and with 3D printing. Time, decay, entropy, and water know few boundaries.





One has to remember the point made by Le Corbusier: really there is no such thing as detail; everything is important: yes, everything.## The concern with 3D printing is that its implementation and all of the issues it raises, can easily distract from a care with simple detailing and other basic issues. We must approach this new method of construction, not with an apologetic, forgiving acceptance, but with a critical rigour that challenges methods, outcomes, and performances to ensure we are not creating problems for the future.





We need to include thinking about: recycling; reuse; retrofitting; refurbishing; repairing; durability; extending; services; maintenance; and new technologies, for these matters are sure to arrive in the future; and we must never forget the broader, more subtle and complex issues of what we are producing. Texts boasting about the process are keen to suggest that whole cities might be 3D printed. We should never forget to ask what our cities should be, in the same way as we should keep questioning ourselves about housing forms and their impacts on well-being, in all of its aspects, both personal and communal.+ It is just too easy to be blinded by the excitement of the new: see – https://voussoirs.blogspot.com/2022/02/the-topography-of-settlement.html. One always has to be questioning circumstances to ensure that matters are not being overlooked; that everything is being accommodated knowingly, optimised and managed appropriately. In this regard, we need to know not only the complete scope of opportunities in 3D printing, but also their limitations, demands, and impacts. It really is just too easy to be euphorically ecstatic with things new, and forgive and forget.



#

See, for example:

https://craftcloud3d.com/

https://www.gizmodo.com.au/2022/03/we-could-start-building-3d-printing-cities-using-concrete-made-with-recycled-glass/ cities

https://www.gizmodo.com.au/2022/03/we-could-start-building-3d-printing-cities-using-concrete-made-with-recycled-glass/


##

Jane B. Drew, in her essay Le Corbusier as I Knew Him, recalled the numerous personal letters Corb used to send her:

I remember much of what was in them: “There is no such thing as detail in architecture, everything counts”;


*

14 MARCH 2022

The reports on 3D printing keep pouring out:

https://hackaday.com/2022/03/09/upgraded-3d-printed-tank-gets-better-drivetrain-and-controls/

https://www.businessinsider.com/photos-icon-new-3d-printed-luxury-home-austin-texas-2022-3

https://hackaday.com/2022/03/13/5-axis-3d-printing-for-the-rest-of-us/

https://scitechdaily.com/next-gen-3d-printed-catalysts-to-propel-hypersonic-flight-speeds-over-3800-mph/

https://www.abc.net.au/news/2022-03-14/qld-brisbane-biotechnology-lab-uses-3d-printing-cancer-patients/100903674

https://m.all3dp.com/2/3d-printer-gantry-simply-explained/


+ We should always ask the Kahn question:

What does . . . want to be?

What does a brick want to be?

What does a home want to be?

What does a city want to be?

The answer, “3D printed,” is not good enough; it is just too crudely simplistic.

We have to try to understand how to honour things – materials, forms, spaces, places, people, . . .


Even a brick wants to be something.
A brick wants to be something.
It aspires.
Even a common, ordinary brick... wants to be something more than it is.
It wants to be something better than it is.

Louis Kahn


If you think of Brick, you say to Brick, ‘What do you want, Brick?’ And Brick says to you, ‘I like an Arch.’ And if you say to Brick, ‘Look, arches are expensive, and I can use a concrete lintel over you. What do you think of that, Brick?’ Brick says, ‘I like an Arch.’ And it’s important, you see, that you honour the material that you use. [..] You can only do it if you honour the brick and glorify the brick instead of shortchanging it.

Louis Kahn - transcribed from the 2003 documentary My Architect: A Son’s Journey by Nathaniel Kahn.


29 MARCH 22

See: https://www.businessinsider.com/photos-luxury-350-square-foot-3d-printed-tiny-home-austin-2022-3 One has to be concerned about the durability of these dribble walls. Might they really make good splashbacks? Are they good surfaces to seal to? Will they provide good insulation? Are they porous?


31 MARCH 2022

3D-printed furniture: see - https://www.designboom.com/design/r3direct-giulia-del-grande-u-s-e-urban-safety-everyday-street-furniture-lucca-03-29-2022/


26 MAY 22

3D printing is seen as the panacea for all of our housing problems: see -https://www.abc.net.au/news/2022-05-26/3d-house-printing-australia-/101103318 Unless this is carefully managed, one can only see the problems being exacerbated. We appear to be just too keen to grasp at new technologies with too much positive thinking, never bothering to ask critical questions about the process or the outcome, assuming only good can come from things exotic, new, and different.

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