The Latest in Sustainable Construction Technologies
In April 2024, the world witnessed a remarkable advancement in sustainable construction technologies as the University of Maine, in collaboration with Oak Ridge National Laboratory (ORNL), unveiled a 3D-printed floor cassette that could replace traditional steel-and-concrete flooring in multi-story buildings. One key innovation in the project was the use of 3D-printed wood material, which offered sustainability benefits.
This innovation, known as the “SM2ART Nfloor cassette”, is strong, lightweight, recyclable, and eco-friendly, making it a game-changer in the construction industry.
Cassette Composition: Natural Materials and Advanced Technology
This breakthrough relies on a blend of bio-based natural materials, including:
- Polylactic Acid (PLA): A biodegradable thermoplastic derived from corn residue.
- Wood Flour: A byproduct of lumber processing, making it a sustainable choice and an integral component of 3D-printed wood material innovations.
Scott Tomlinson, a structural engineer at the Advanced Structures and Composites Center (ASCC) at the University of Maine, stated:
“The PLA and wood flour blend is an excellent material for producing recyclable, large-format additively manufactured parts.”
He further added:
“This single-piece floor assembly is stiffer and provides an improved walking experience compared to the steel-concrete assembly it replaces.”
Manufacturing: Speed, Precision, and Cost Savings
The cassette was manufactured using a giant 3D printer known as “Factory of the Future 1.0”, which was unveiled by the University of Maine in April 2024. This printer has an unprecedented capability to print massive structures with dimensions of:
- 96 feet (29.3 meters) in length
- 32 feet (9.75 meters) in width
- 18 feet (5.5 meters) in height
The printing process took only 30 hours, resulting in a 33% labour savings compared to traditional construction methods. Additionally, the cassette was designed with pre-cut openings for electrical, plumbing, and ventilation systems, eliminating the need for costly modifications. It’s a fine example of 3D-printed wood material efficiency.
Katie Copenhaver, a researcher at Oak Ridge National Laboratory (ORNL), explained:
“By utilizing bio-based, large-scale 3D printing, we replaced an assembly made from 31 parts and three materials with a single-material floor panel that is ecologically friendly and with the same strength as traditional steel floor fabrication.”
She also emphasized:
“3D printing can save time and money by printing the floor cassette with cutouts designed into the finished product, reducing the need for manual adjustments.”
Inspiration Behind the Project: Engineering Meets Architecture
The project idea originated from SHoP Architects, a New York-based architectural design firm, which challenged researchers to find a more efficient and sustainable way to produce floor panels using additive manufacturing with the innovative use of 3D-printed wood material as part of their strategy.
Copenhaver commented:
“The idea came when the SHoP Architects team asked if we could mass-produce floor panels more efficiently with greener materials and additive manufacturing.”
Next Steps: Advancing Sustainable Construction
While the project is still in its prototype stage, researchers are working on additional improvements, including:
- Enhancing fire resistance
- Improving thermal insulation
- Developing advanced production techniques for increased efficiency and quality, particularly focusing on 3D-printed wood material advancements.
In conclusion, Tomlinson stated:
“This technology holds a lot of promise for the future of sustainable buildings.”
Summary Table: Key Information on the 3D-Printed Floor Cassette
| Aspect | Details |
|---|---|
| Announcement Date | April 2024 |
| Developing Institutions | University of Maine (ASCC) and Oak Ridge National Laboratory (ORNL) |
| Material Used | Polylactic Acid (PLA) + Wood Flour |
| Printing Duration | 30 hours |
| Labour Savings | 33% compared to traditional construction |
| Printer Dimensions | 96 ft × 32 ft × 18 ft |
| Design Features | Lighter, stronger, pre-cut openings for utilities, recyclable |
| Next Development Stages | Enhancing fire resistance, thermal insulation, and production techniques |
| Project Origin | SHoP Architects – New York |
This innovation marks a significant leap in sustainable construction, paving the way for a future of more efficient and environmentally conscious building methods.
