Oak Ridge National Laboratory’s Manufacturing Demonstration Facility has partnered with Gate Precast Company and AES to fabricate large-scale, concrete patterns using additive manufacturing. The project explores alternatives to conventional precast concrete pattern manufacturing. Concrete patterns are currently built using hardwood, cost approximately $10,000 per pattern, and only provide five to ten concrete structures before they no longer produce structurally accurate parts. This is time, cost, and resource inefficient. With additive manufacturing, the same precast concrete patters, measuring 9’ x 4’ x 1’, can be fabricated in approximately nine hours, cost approximately $6,000, and first test patterns have withstood more than thirty concrete pours without any sign of degradation. These patterns will be used to fabricate structural window frames for the Domino Sugar Refinery redevelopment in New York City. The façade will require approximately 70 different pattern shapes, so this is the ideal opportunity to evaluate additive manufacturing verses conventional pattern manufacturing.
- Define the advantages associated with additive manufactured molds, patterns, and tools verses traditional tooling techniques.
- Understand and describe the AM tooling process on a Big Area Additive Manufacturing system.