Researchers from the Polytechnic University of Valencia (UPV) have devised and patented a new system for manufacturing beams that promises to “revolutionize” the architecture, building and civil engineering sectors. They are made of 3D printed plastic pieces that can be assembled as if they were Lego modules and a layer of high-performance concrete in the most compressed area.
Its advantages, according to its creators, are multiple: they weigh up to 80% less than concrete or metal beams, which means that large cranes or trucks are not necessary to transport and install them; save time and costs in labor and material; and can be printed and assembled on-site, making it easy to install anywhere, no matter how difficult it is to access. To all this is added that it takes advantage of recycled plastics as raw material, giving a new life to this product and thus moving towards a more sustainable construction.
The development of these innovative beams is the result of almost three years of research. “Our objective was to propose an alternative to the current reinforced concrete structures. These are made up of profiles that are built over the entire length of the piece, which requires expensive installations and is difficult to transport “, points out José Ramón Albiol, professor at the Higher Technical School of Building Engineering (ETSIE) of the Polytechnic University of Valencia. After many hours of trials and tests, the combination of 3D printing, plastics and concrete offered optimal results. And it was in October of last year when they patented the system.
Its main novelty is found in the polymeric profile of the beam, composed of multiple longitudinal segments that can be assembled and concreted in the place where the structure is to be installed. The beam is reinforced with elements that guarantee the rigidity of the structure and also does not have any metallic component. “In this way, corrosion is avoided, weight is reduced and working time is simplified,” adds Xavier Mas, from the Heritage Restoration Institute (IRP) of the Polytechnic University of Valencia.
The system also eliminates the need for expensive formwork and formwork, allowing you to work without cutting off traffic on the infrastructure you are working on. “In addition, this solution allows reducing the labor and auxiliary resources required, which translates into considerable cost and time savings”, says José Luis Bonet, from the University Institute of Concrete Science and Technology (ICITECH) of the Polytechnic University of Valencia.
A “human” structure
Another novelty of the system devised by UPV researchers is found in the internal structure of the polymer profiles. “It is a honeycomb structure, which allows reducing the plastic material used – and therefore its weight – while maintaining structural rigidity,” says Albiol.
This alveolar geometry is inspired by that of human bone in the epiphysis area, where there is a part of the spongy bone layer, with a trabecular framework – this would be the alveolar formation – and the thickest outer layer where the compact bone is. “And this is what we have transferred to these revolutionary beams, specifically to the profiles. It is a very intelligent natural system and its replication in these beams gives them, with a low structural weight, a very high mechanical capacity. ”, Adds José Ramón Albiol.
Custom parts anywhere
3D printing allows the manufacture of custom parts very close to their point of application, which also simplifies transport, saves costs and facilitates customization. “Being able to customize the beams in-situ allows the characteristics of each one of them to be adapted to the structural needs of each point of application. The possibility of recycling polymeric materials to make the beams significantly reduces their carbon footprint ”, concludes Miguel Sánchez from the UPV’s Department of Computer Science and Technology (DISCA).
Source: Asociacion RUVID
They manufacture new 3D-printed beams inspired by Lego pieces and the human body
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