Background:

This research project explores the design and fabrication of a large-scale extruder for 3D printing with natural fibers, in collaboration with the Xylaprint research project run by the Institute of Landscape Architecture. The project’s primary goal is to advance sustainable construction technology by developing an extruder capable of processing biodegradable materials for automated building applications. Leveraging prior collaborative research from Xylaprint and IGMR, the project addresses a key challenge in the robotization of construction: integrating natural materials effectively into 3D printing systems at an architectural scale. This thesis will focus on designing and testing at least two extruder prototypes. This will involve close integration with a KUKA robotic arm and a control system developed through microcontrollers and sensors, allowing for real-time adjustments during the printing process. Through these trials, we aim to create a functional extruder prototype capable of sustained performance in real-world applications. The successful implementation of this research significantly contributes to sustainable building practices, supporting industry efforts to incorporate ecological materials and robotic fabrication technologies.

You can find more information about the project in the following article. WDR - Holz Häuser aus 3D Drucker

Possible work packages:

• Literature research and familiarization with the project
• Mechanical design and improvement of a large-scale extruder
• Integration of sensor systems
• Manufacturing and testing
• Documentation

Requirements:

• Mechanical engineering, CES or comparable engineering studies
• Independent and systematic way of working
• Interest in robotics and additive manufacturing
• Ideally previous knowledge with the development of mechatronic systems

We offer:

• Development close to the application
• Professional and personal development through intensive support
• Pleasant and personal working atmosphere