Ben Robinson Stadmaker's Printville

BEN ROBINSON [Re_Map]1090

ii

Welcome To

iii

Print Ville

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DUS ARCHITECTS The KamerMaker Dutch: The Room Maker

THESIS PROJECT

The StadMaker Dutch: The Town Maker

Contents

0.1

01-19

Step 1- The System

20-23

Step 2- Pick Your Volume

24-45

Step 3- Pick Your Plot

46-51

Step 4- Customisation

52-79

Step 5- Interior Customisation

80-95

Step 6- Housing Standards

96-113

Step 7- Unit Development

114-159

Appendix-

160-163

Not Just a House

Your Printed Home

Imagine a new way of thinking

££££

££££

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££££

Imagine a housing system where the driving force behind the price of a house was simply the weight in material used to produce it, where the traditional house on the left cost the same as the elaborate house on the right. This is now the reality with

StadMaker 3

StadMaker If you can think it We can print it!

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We welcome you to view StadMakers revolutionary new housing system 5

Imagine a place where you could 3D print a new chair or table for your house whenever you wanted.

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StadMaker’s PrintVille Here is your opportunity to reserve a plot and become part of the world’s first 3D printed housing community.

StadMaker Bloom / Emergin Objects 5Story Apartment Building // RMIT Quake Columns // Emerging Objects Steel Structural Node // Arup 3D Printed House // BetAbram 10 Houses in a Day // WinSun 3D Print Canal House // DUS Architects Endograft // StudioSmith CyBe Digital Grotesque // Hansmeyer + Dillenburger Nematox System // Holger Strauss ProtoHouse 1.0 // Softkill Design KamerMaker // DUS Architects Stone Spray Robot // IAAC Organic Printed Brick // Biomason

Year

Planter Brick // Rael San Fratello Architects Radiolaria Pavilion // D-shape +Shiro Freeform Construction // Loughborough IMCRC D-Shape Printed // Enrico Dini

Contour Crafting // Dr. Khoshnevis 99

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StadMaker, in association with DUS Architects, introduce you to

PrintVille the world’s first 3D Printed community, which will bring production back to the heart of Runcorn.

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This is not 3D printing for the sake of 3D printing

Conventional

MANUFACTuRING

PROTOTY

DESIGN TIME

MANUFACTURING

DESIGN

PROTOTYPE

3D Printing

No difference in cost or time.

MULTIPLE Prototypes produced cheaply and quickly for field testing.

8

If all designs were prototyped the cost would be quadrupled and assessment would take place one at a time

{

x4 TEST

FEEDBACK

x4 TEST

Only ONE design is selected for prototyping due to cost, time and tooling.

FEEDBACK

=

YPE

TESTING

TESTING

PRODUCTION

=

} TEST

FEEDBACK SIMULTANEOUS Testing of all prototypes means data is rapidly fed back into the process and quickly tailored to suit application.

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PRODUCTION

10

Interested?

Come and take a tour

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This ground breaking project will be rolled out across Runcorn over the next decade - the first phase of which is on site now.

There are still over 20 plots remaining, so come work along side us to create not just your future house, but your printed home.

B1

B2 12

StadMaker Future Masterplan 1:5000 at A1

Key

D4

Production Facility

Phase 1 On site

D3 D1 C3

D2

B

Phase B 2017

C

Phase B 2018

D

Phase C 2019

c4

C2

Future printed Housing

B3 Communal facilities

B4 C1

School

13 N

Phase 1- Growth

14

Feedback

Complexity

Print size

Cluster Size

Time- 2015

Phase1-A The Sculpture Park, the first of the 3D prints are exhibited to the public to encourage a greater understanding of the technology that is being introduced to Runcorn.

Phase1-B The first and smallest cluster is now complete, home to houses designed by our partners DUS Architects.

Phase 1-C & D On site Now The first of the full size printed community clusters.

Late 2016

Phase 1-E- Taking Orders Now!

Phase 1-F- The Printed Apartment complex

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What will you see in a 3D printed community cluster?

Th Av e 20 ail 3 ibl e

Clu ste rO rbit al Ro ad Pl

ot

Sh

ar

ed

Pe

de

&

Ca

rR

The 101 Availible

ze

To

str

ian

Si

k La e h t

e

ou

te

ce

al

m

m

Co

un

a Sp

Plastic to PrintRecycling point

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Orbital Road To reduce car traffic, orbit roads navigate around each cluster creating a safe and quiet internal environment.

Plot Size - Your plot, your rules.

If you want space to park 2 cars outside your house, no problem.

If you want a printed climbing frame for your children, no problem.

As long as your planned work does not breach any of the rules within the rule book, you are free to include what you want.

KamerMaker Once your 3D printed house is delivered, the 3D printing does not need to stop.

At the centre of each cluster is a KamerMaker 3D Printer, allowing you to print furniture and upgrades for your house easily, just meters from your front door.

Shared Pedestrian & Vehicle route, These shared spaces are proven to create safer spaces for pedestrians and help to form a safe and pleasant environment.

Plastic to Print Recycling Point.

Each cluster has direct access to the plastic recycling point where plastics will be melted down and recycled into print filament to be used in the communal KamerMaker.

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You can become a part of PrintVille in 7 easy steps

?

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Step 1 // Understand how the system works Being involved requires a higher degree of participation than your average new build, so it is important you understand the process before we get started.

The

203

Step 2 // Pick Your Volume

The

The 169

The 101 Plot Available

101

Why be limited to a 2 bed or a 3 bed home? Pick from - the 203, the 169 or the 101 - and shape it to suit your individual needs.

Step 3 // Pick Your Plot Choose from the available plots for each of the three volume sizes.

Step 4 // CustomisationWork alongside StadMaker to start shaping your truly individual printed home.

Step 5 // Internal CustomisationWhether you want to embrace plastic furniture or stick to something more traditional.

Step 6 // Material Choice Print material can be mixed with a library of different additives to get the colour and effect you are looking for. If you use recycled material you may even be eligible for a government grant.

Step 7 // Production and assembly Your 3D printed home is now ready to be assembled on site.

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20

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The System 21

System diagram

Clients can work along side a design team to help guide the production of customised elements.

As each house is customised and therefore different. There will be experiences to be taken from each house produced with improvements feed back into the system.

Resulting in constant real time R&D which is current unachievable with current construction methods

This Diagram describes the process you will go through as a client in the process of designing and printing your very own home.

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The design and Customisation system caters for the selection of the housing modules as well as the Customisation of elements or selection of pre designed elements from a database.

Within the printing stage, print materials can be selected and configured for printing. The weight of the printed produced can then be determined.

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24

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Pick Your Volume

The volumes 203

The

203m2 GF- 67 1F- 68 2F- 31 Roof Garden- 32

The

The 169

169

The

The 203

101

169m2 GF- 61 1F- 39 Roof Garden- 23 2F- 39

The 101 101m2 GF- 45 1F- 46

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Three contrasting volumes that aim to cater for a wide variety of individual needs. The increase in size does not need to correspond to an increase in the number of bedrooms. Perhaps you work from home? Or simply enjoy open plan living. The 203 can be configured as a 2 bed with a office or a 4 bed house.

The choice is yours.

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From a volume to a customised home 203

The

Initial Volume

11000 3240

3240

250

The 203

2350

3600

2350

Brain 2 m²

The 203 WC 3 m²

Pre-customised floor plans

7800 2350

The 203 G Floor 62 m²

4040

2350

2020

3300

4040

4450

3950

250

3950

2000

Customisable parameters

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STADMAKER

Please refer to the separate rule book for a full explanation of all the rules.

_Rule Book

The Rule Book defines the elements and parameters for customisation within each of the three volumes.

It is important to familiarise yourself with the rule book, but don’t worry, you will not be left alone to customise your home. The StadMaker team will work alongside you to ensure your design meets all the requirements of the rule book.

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The rule book Examples

CUSTOMISATION RULE 00: Customisation freedom is catered for as long as the said customisation does not impact negatively on the final sustainable code rating.

01:

Customisation that aims to improve the sustainable code rating is encouraged and supported.

Rule 02: Wall Zones

Cust Surface

External walls consist of 3 key zones. The customisable zone, controlled zone and structural zone. Understanding these zones is the first key step in understanding how customisation takes places within your STADMAKER Home.

Structural Element Controlled surface servicing insulation

Wall depth

Rule 03: Customisation Depth

450 115

The standard depth of an external customised surface is 115mm. There is 300mm of additional customisation depth available. Any distance beyond this will extend too far into surrounding land.

The nternal customisable depth is 60mm, however this includes only internal wall finish and does not take into account printed items such as storage and shelves.

300

275

60

115

450 Max Cust Depth

Rule 04: Window Location & Size The allowed location of windows are shown in white. No matter what the size of the allowed opening (in this example 3950mm) the maximum span of a single window is limited to 2000mm due to the nature of the construction.

Other than this the shape of a window is not controlled.

3950

2000

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Rule 07: Door Locations The allowed locations of external doors are shown in blue. Their positioning along this stretch will depend on your chosen interior layout. This is something your project Architects will work alongside you to set out.

Rule 08: Circulation Space The location of circulation space internally is not governed. However, circulation must be 1000mm at its narrowest point. This ensures housing meets the standards set out in Homes for Life.

Living Space

Printed Storage Unit

1000mm

Rule 10: Location of The Brain The location of the Brain is fixed. This allows for a set location for services to be installed on a plot and into a house.

Brain

Rule 11: Location of Wet Services

Brain

WC Eat

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Kitchens, toilets and bathrooms must share a wall with The Brain, or its riser on the above floor. This ensures a sensible and economical distribution of services.

The Brain

Understanding the plans:

11000 3240

3240

250

The 203

2350

3600

2350

Brain 2 m²

The 203 WC 3 m²

2020

G Floor 62 m²

The only predefined space 2350

2350

The 203

4040

3300

4040

4450

3950

250

3950

2000

Brain

WC Eat

Rule 11:Location of Wet Services Kitchens, Toilets and Bathrooms must share a wall with The Brain, or its riser on the above floor. This ensures a sensible and economical distribution of services.

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The Brain is the only space with volumes that are predetermined.

This is because it is the point at which services enter and exit your home. By keeping the Brain in the same place in every home, it makes the process of installation and maintenance more efficient.

For technical information regarding the Brain please refer to step 7.

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The 203

Please refer to the rule book for the key and full set of rules relating to floor plans.

The

203

11000 3240

3240

250

The 203

2350

3600

2350

Brain 2 m²

The 203 WC 3 m²

The 203 GF

7800

67m2

2350

The 203 G Floor 62 m²

4040

2350

2020

3300

4040

4450

3950

250

3950

2000

275 300 125 50 450

2750

300

2000 2800

2050

The 203 Section 300

2800

2050

450

3260

375

3260

450

0

5 34

11000 250

3235

2350

300

68m2

7800

The 203 1F

2445

2350

855

3240

1st Floor 68 m²

2350

3300

2350

The 203 10100

3950

250

3950

2000

11000 250

3235

2350

300

31m2

7800

The 203 2F

2445

2350

855

3240

1st Floor 68 m²

2350

3300

2350

The 203 10100

3950

250

3950

2000

3240

3240

2000

32m2

4000

4000

The 203 Roof Terrace 32 m²

11000

35

2160

2160

2nd Floor 31 m²

250

The 203 Roof

The 203

The 203

Looking for something more traditional?

The

203

No problem!

If a traditional layout works for you, we have a number of floor plan configurations for each of the starting volumes. Our traditional floor plans meet the latest in space standards set out by the RIBA Case for Space as well as the Code for Sustainable Homes.

Just ask one of our representatives for more information.

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The 203

Example of a traditional configuration (Not to scale)

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The 169

The

Please refer to the rule book for the key and full set of rules relating to floor plans.

169

9140 2000

9200

2085

1485

3455 7550

1480 3445

3860

1195

The 169

The 169

G Floor 61 m²

The Brain

The 169A

The 169A

2 m²

3 m²

Brain

The 169A G Floor 58 m²

WC

1510

2 m²

4015

2450

3150

4240

2570

2485 1650

825

825

2485

3860

1200 5770

3105

The 169 GF 61m2

460

2700

300

2800

300

2800

The 169 Section 450

5300

375

3260

325

0

5 38

The 169 1F 39m2 RG- 23m2

3650

5750 3850

540

3675

The 169

The 169 Roof Terrace 23 m²

The 169A

The 169A

1st Floor 40 m²

Roof Terrace 26 m²

1650

3035

2140

2140

9200

1st Floor 39 m²

4310 7550

1195

3160

3160

3065

3850

3860

3860

2000

2000

The 169 2F 39m2

3850

The 169

3160

3160

3060

3850

The 169A

2nd Floor 39 m²

3860

3160

3035

3160

2nd Floor 40 m²

3860 2000

2000 5750

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The 169

Looking for something more traditional?

The

169

No problem!

If a traditional layout works for you, we have a number of floor plan configurations for each of the starting volumes. Our traditional floor plans meet the latest in space standards set out by the RIBA Case for Space as well as the Code for Sustainable Homes.

Just ask one of our representatives for more information.

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The 169

Example of a traditional configuration (Not to scale)

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The 101

Please refer to the rule book for the key and full set of rules relating to floor plans.

The

101

7615 2000

2000

2710

2640

2450

2740

2740

2450

The 101A

3775

Brain

The 101 G Floor 45 m²

The 101

The 101

Brain

Store

1 m²

1 m²

The 101A

2 m²

7550

3200

G Floor 45 m²

The 101A WC 2 m²

2075

WC

4825

1910

The 101

3545

3 m²

2525

200

2475 1650

860

860

2785

2525

The 101 GF 45m2

500

2000 2850

300

2800 2050

The 101 Section 45m2 450

3150

375

3450

325

0

5 42

2000 2450

The 101A

The 101

1st Floor 43 m²

2825

1030

3540

1st Floor 46 m²

The 101

The 101A Balcony 7 m²

785

Balcony 4 m²

2525

The 101 GF 46m2

43

4125

2730

2640

5360

2215

3675

2190

2730

1110

The 203

Looking for something more traditional?

The

101

No problem!

If a traditional layout works for you, we have a number of floor plan configurations for each of the starting volumes. Our traditional floor plans meet the latest in space standards set out by the RIBA Case for Space as well as the Code for Sustainable Homes.

Just ask one of our representatives for more information.

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The 101

Example of a traditional configuration (Not to scale)

45

46

Pick Your Plot 47

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Developed Plots

The DUS House

The Wood House

The Normal House

The Wavy House

The Solar House

The Blob House

The Purple House

The Tudor House

The Artists House

Available Plots 203

The

The 203

The

169

The

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101

The 169

The 101

Why not take a walking tour of the site to see the houses that have already been printed.

Looking for inspiration?

Then take a look at this elevation of a completed street...

The

203

The 203 ‘The Normal House’ The Smith Family

The

The 169 169

‘The Solar House’ Dr Yvonne Grunder

The

The 169 169

‘The Artists House’ Tom Gilmour

The

101

The 169 ‘The Tudor House’ The Buckets

StadMaker Elevation 1:100 at A1

Each of these completed houses are strikingly individual, yet all meet the requirements set out in the rule book. If you can think of it, we can print it!

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Customisation 53

How does it work?

Our state of the art software can take your photographs and images and translate them into a 3D form in 7 steps.

A brick Wall?

We can print it

You like Erwin?

We can copy it

Or you want to advertise you art On your house?

We can do it

Step 1- Send us your image

Step 2- Translate image

Step 3- Select your volume

If you have a design in mind, whether it is your favourite piece or art or architectural style, simply email it to us atPrintville@stadmaker.co.uk

Our software will translate your images into a bitmap file. This allows us to set the level of extrusion based on the colour shade from white to black.

The 203, The 169 or The 101

Step 4- Scripted Design

Your selected design can then be applied to your chosen volume using o advanced script-based modeling tha has been developed in house.

our at

Step 5- Design consultation

Step 6- Printing

Step 7- Assembly

Through a series of design consultations, your design will be honed until you are happy.

Once the design has been finalised it can be sent to the on-site printers.

The printed elements will then be transported to site and assembled in less than one working week.

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How does it work?

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This method allows us to simply overlay your designs onto the predefined facade structural elements. This allows for infinite variation in design, whilst the structural system remains the same throughout.

For more information on the structural system please see step 7.

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The Art House

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What will yours say about

You?

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Existing clients Client Bio Tom Gilmour- Artist.

Tom is a artist who grew up in Runcorn.

His tattoo-inspired art has led him to do work for numerous clothing lines as well as launching his own websitehttp://www.tomgilmour.com Tom was looking to design a house that was not only a personal statement but also a house that advertises his own work.

Bespoke artwork Tom created a bespoke piece of art that was drawn specifically to be turned into the facade of his future house.

Working alongside Tom, we draped the artwork around the 169 volume to create a totally unique design.

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Client Specific customisation parameters

Artwork Scale Extrusion Depth Displacement Angle

User interface Our software has a simple and intuitive user interface that Tom got stuck into when designing his house.

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Drape

What if you don’t have a design in mind?

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If you don’t have a design idea for us to work with, you can still create your dream home using our other modes of customisation: 1- StadMaker database 2- In-house environmental modeling 65

Existing clients Client Bio Mr & Mrs Smith The Smiths where born and bred in Runcorn. Alan Smith worked at the local gas plant until it shut down and was forced to retire.

“All i want is a traditional detached house with room for the grandchildren�

Having lived in a rundown ex-council house that is being demolished as part of the PrintVille regeneration work, the Smiths have what many would consider a simple wish - and that is to have a traditional detached brick house.

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149 110

Using the StadMaker online database Export

MakerStad

Online Database

Load File

Facades

Finishes

Furnishings

Artwork Scale Extrusion Depth Displacement Angle Drape

The Smiths took advantage of our online database of image samples, including numerous images of brickwork buildings from Runcorn Old Town.

The Smiths were able to select their favourite design elements to form their dream house.

Specific Customisation Parameters

Brick Type A

B

C

D

Brick Pattern The material choice is key to the aesthetical finish of the house and brick dust from the recycled brick will be used to create a brick-like texture.

(See Step 6 for more information)

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A

B

C

D

Window Type A

B

C

D

The Normal House

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What will yours say about

You?

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The Solar House

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Other ways to customise your home

Client Bio Dr Yvonne Grunder Is a Doctor of physics at the Stephenson Institute for Renewable Energy at the University of Liverpool.

Dr Grunder has been involved in the installation of PV systems across the University campus.

Her passion is renewable energy, particularly PV Arrays. She has seen the StadMaker project as a means to take her passion for work into the form of her home by using our environmental modeling software.

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Environmental modeling MakerStad

Analysis Software

Load File

Peak Radiation

<

>

Value Range: 110.0 - 500.0 Wh/m2

+

-

Modeling space

Wh/m2 500+ 461 422 383 344 305 266 227 188 149 110

Export

MakerStad

Online Database

Load File

Facades

Finishes

Furnishings

1//

Once you have selected your plot we take the exact latitude and longitudinal co-ordinates of your plot.

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Environmental modeling 2//

Our adaptive solar facade panels are then placed into our environmental modeling software with the exact latitude and longitude co-ordinates.

It then orientates them into individual facade elements to ensure each element is perfectly orientated to gain maximum solar energy.

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3// The software ensures each element catches maximum solar rays without blocking solar rays from its neighbours This means that every single house designed using this software is unique. As the individual latitude and longitude co-ordinates ensure this individuality.

See appendix for full results

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Enviromental modeling 2//

Wh/m2 500+ 461 422 383 344 305 266 227 188 149 110

3//

Wh/m2 900+ 840 780 720 660 600 540 480 420 360 300

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4// Wh/m2 800+ 732 664 596 528 460 392 324 256 188 120

5//

Wh/m2 800+ 730 660 590 520 450 380 310 240 170 100

6//

Wh/m2 800+ 732 664 596 528 460 392 324 256 188 120

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1:20 Facade components

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79

80

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Interior Customisation 81

StadMakerâ&#x20AC;&#x2122;s online database Furnishing

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Embrace the plastic!

We have a database of 3D printed furniture that we can print as part of your home design. Here are a few examples.

Or work alongside us to design your own.

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The Bedroom Unit

Open plan bedroom Do you like the idea of open plan living? Why not turn your bedroom into a grand open space with this integrated bedroom and bathroom unit?

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The Potato Wall

Green fingers Do you like growing your own food?

What if you could grow potatoes in a wall that has been 3D printed in a bioplastic that contains 30% potato starch? With StadMaker you can!!

For information on potato filament please see step 6

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The Print Desk

Working from home?

Or do you just enjoy printing?

The print desk is an elegant 3D Printed desk that literally grows out of the walls it sits against.

This may seem strange, but with 3D printing we can literally incorporate furniture into the walls and print them as a single element.

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The Stairs

They donâ&#x20AC;&#x2122;t need to be normal.

Stairs are often simply just a functional element. But they donâ&#x20AC;&#x2122;t need to be.

With Stadmaker, a bespoke staircase costs the same as a plain one - you just pay for the material you print!

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Or something for the 3D Print enthusiasts with open(filename, “w”) as f: for line in lines: if not (‘M84’ in line or ‘M25’ in line): f.write(line) if ‘FLAVOR:UltiGCode’ in line: #Flavor is UltiGCode! No reset of values no_reset = 1 if ‘;TweakAtZ-state’ in line: #checks for state change comment state = getValue(line, ‘;TweakAtZ-state’, state) if ‘;Small layer’ in line: #checks for begin of Cool Head Lift old_state = state state = 0 if (‘G4’ in line) and old_state > -1: state = old_state old_state = -1 if ‘;LAYER:’ in line: #new layer no. found layer = getValue(line, ‘;LAYER:’, layer) if targetL_i > -100000: #target selected by layer no. if state == 2 and layer >= targetL_i: #determine targetZ from layer no. targetZ = z + 0.001 if (getValue(line, ‘T’, None) is not None) and (getValue(line, ‘M’, None) is None): #looking for single T-command pres_ext = getValue(line, ‘T’, pres_ext) if ‘M190’ in line or ‘M140’ in line and state < 3: #looking for bed temp, stops after target z is passed old_platformTemp = getValue(line, ‘S’, old_platformTemp) if ‘M109’ in line or ‘M104’ in line and state < 3: #looking for extruder temp, stops after target z is passed if getValue(line, ‘T’, pres_ext) == 0: old_extruderOne = getValue(line, ‘S’, old_extruderOne) elif getValue(line, ‘T’, pres_ext) == 1: old_extruderTwo = getValue(line, ‘S’, old_extruderTwo) #Ex3 elif getValue(line, ‘T’, pres_ext) == 2: #Ex3 old_extruderThree = getValue(line, ‘S’, old_extruderThree) if ‘M107’ in line: #fan is stopped; is always updated in order not to miss switch off for next object old_fanSpeed = 0 if ‘M106’ in line and state < 3: #looking for fan speed old_fanSpeed = getValue(line, ‘S’, old_fanSpeed) if ‘M221’ in line and state < 3: #looking for flow rate tmp_extruder = getValue(line,’T’,None) if tmp_extruder == None: #check if extruder is specified old_flowrate = getValue(line, ‘S’, old_flowrate) else: if tmp_extruder == 0: #first extruder old_flowrateOne = getValue(line, ‘S’, old_flowrateOne) if tmp_extruder == 1: #second extruder old_flowrateOne = getValue(line, ‘S’, old_flowrateOne) if (‘M84’ in line or ‘M25’ in line): if state>0 and speed is not None and speed != ‘’: #’finish’ commands for UM Original and UM2 f.write(“M220 S100 ; speed reset to 100% at the end of print\n”); f.write(“M117 \n”) f.write(line) if ‘G1’ in line or ‘G0’ in line: newZ = getValue(line, ‘Z’, z) x = getValue(line, ‘X’, None) y = getValue(line, ‘Y’, None) if (newZ != z) and (x is not None) and (y is not None): #no tweaking on retraction hops

For the full code please see the appendix

With this script we have devloped in house, we have taken a common 3D print error- under extrusion , and transformed it into a controlled method of creating beautiful and function partionwall and railing.

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Not only is it more beautiful that a generic wall but it uses up to 70% less material due to its bone like structure.

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The Under Extruded Wall

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Potatoware

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Why stop with the stairs?

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Embrace the plastic

Here at StadMaker we hope you embrace the plastic in the same way as Dr Yvonne Grunder. Every item you can see in this photograph has been 3D printed specifically for the solar house. Dr Grunder was dedicated to maximise the use of recycled plastics within her design to gain the highest possible sustainability rating.

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Concrete screed floor with recycled plastic scrap aggregate

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â&#x20AC;&#x153;Keystonesâ&#x20AC;? 3D printed Table designed by friends of DUS Architects Studio Minale-Maeda

Potatoware

By Ben Robinson & DUS Architects

Or remain traditional

A StadMaker home does not need to look like something from the future. We understand that people have their own taste, style and favourite belongings.

Therefore your StadMaker home does not have to have the look and feel of plastic. You can finish it with traditional materials or use special printing techniques to recreate traditional materials.

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Traditional table printed in mahogany additive plastic filament

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Shag pile carpet

Picture hanging can be incorporated into the printed walls

Wallpaper can be easily applied to our printed walls or you could even print the pattern

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Material Choices 99

What is Bio Plastic / PLA?

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Product By

ac Extr tion

w Mater ia Ra

Refining

l

w Materi a Ra l

la BioP stic

Renewal

Disposal

duction Pro

PLA - Poly(lactic acid) or polylactide A form of bio-plastic, particularly a biodegradable thermoplastic (under specific industrial conditions).

It comes from renewable plant resources, such as corn starch, tapioca roots, sugarcane chips or any other high starch foods.

In 2010, PLA had the second highest consumption volume of any bio-plastic of the world.

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How is it made?

Colorfabb

Small Scale Production Line

Raw material heater and Extruder

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Material extrusion and cooling

Laser monitored quality control procedure

Our Material Partners based in the Netherlands have developed a system to mass produce additive based bio-plastic allowing us to quickly and easily add colour material additives to create the finish you desire.

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<70%

<30% 104

How do you add colour / materials?

Base Material

Macromelt 6900E a non hazardous and biodegradable bio-plastic (biodegradable in specific conditions, not under normal use).

Additive material

If you can think of it we can add it (exclusion apply to hazardous additives or additives that could impact upon the structural integrity of the plastic).

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Material mix

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Base Material Macromelt 6900E is a near translucent base material.

Additive MaterialRecycled car tyres This ratio of tyre pellets to Macromelt 6900E is all that is needed to change the colour of the plastic from translucent to a deep black.

Additional tyre material can be added up to a value of 30% to bring out the texture and feel of rubber to the printed surface..

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The Solar House Material makeup Printed layers- 9135 Base material- Macromelt 6900E derived from Dutch Linseed oil.

Filler Material- 7 Local sourced recycled materials

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The Normal House Material makeup Reminisce

Locally sourced additive material

The Smiths reminisced of the houses they grew up in as children - traditional two up two down.

Bricks were collected from houses demolished within the Runcorn area.

The Runcorn brick print filament

The brick is then ground down into dust and mixed with the Macromelt 6900E to form the Runcorn Brick Filament

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1:20 Structural Model

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The Tudor House Material makeup The unaffordable wish - Halton Village

StadMaker picture mapping

The Buckets have always dreamed of living in Halton Village, but have simply not been able to afford a property.

But now StadMaker is able to recreate their dream home by photo-mapping the surface of a tudor house and recreating it in our state of the art software.

UK sourced waste oak wood shavings

We sourced oak wood shavings from a UK based furniture manufacturer to recreate the tudor style of the past with the home of the future.

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1:50 Model

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Material choice

Whatever your style, we can find and develop a colour or material that is personal to you.

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Production & Assembly 117

The KamerMaker V1

The KamerMaker is the 3D printer developedbyDUSArchitectsthat inspired StadMaker along with DUS to develop The StadMaker and begin production of housing on a much large scale.

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The KamerMaker (Room Builder)

The KamerMaker is simply too small to be used for the full scale production of the housing components, but instead it is utilised at the center of every housing cluster as a communal 3D printer.

3100 16 00

00 16

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The StadMaker (Town Builder) 9 Print heads combine to form one super quick 3D printed increase print speed by 90%.

The StadMaker measures in at double the print bed size and an increase in 600mm in buildable height.

3800 36 00

00 36 121

Yes thats right, our innovative construction system can really save 75% on raw materials. By using state of the art software andbyutilisingthemanybenefits offered by 3D printing, we are able to optimise the structure to only place material where it is structurally required.

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75%* Reduction in Raw Materials With our innovative optimised Structural system *Average saving 65%

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The structural system 1:20

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Structural system // Macro 1

2

3

4

Print element Junction

The 203 Brain 2 m²

12

5

The 203 WC 3 m²

11

6

The 203 G Floor 62 m²

Structural column

Structural lintel 10

9

8

7

Printed structural elements in The 203 GF- 12 1F- 12 2F- 10 RG- 6 R- 8

Largest printed panel 3600, 3100, 450 mm

Although the Stadmaker construction system utilises world leading technology, the underling structural system is based on simple and traditional construction methods.

The facade elements simply slot round the structural system of columns, beams and lintels that support the overall load of each 3D printed house.

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4

5

3

6

2 1

7 8

12 11 127

9 10

Structural system // Meso 1:10

A

B

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1 2 3

4

5

6

A

7

10 A 11

812 13 129

9

Structural system // Micro optimised columns 1:20

Pre-optimised form

Displacement: Max 2.083e-00m

Support material

3D printed mould of optimised form

Poured concrete structural infill 130

Displacement: Max 2.083e-00m

Tension & Compression

Factor of Safety

Max 2.000e + 02 MPa

Min -1.772e +02 MPa

Here you can see our optimising software in action. Material that does not carry load is removed to leave the most optimal and efficient shape (safety is monitored highly as shown above). This process saves

65% in material 131

Structural system // Micro optimised columns 1:20

Pre-optimised

Run 1 of optimisation

Run 2 optimisa

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of ation

Section

Showing poured concrete internally

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Final run

With facade panel fixings

Structural system // Micro optimised lintel 1:20 Pre-optimised form

Poured concrete structural infill

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Tension & Compression Max7.394e + 02 Pa

Min -1.667e +03 Pa

Displacement:

1

Max 1.483e-08m

2

3

4

70% material 135

savings

Structural system // Micro 1:20

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The structural system 1:20

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The structural system 1:20

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Structural axonometric The Solar House

1// External floor tiles (material defined by occupant) to protect the bottom of the printed walls from ground conditions.

2// Aluminum capping strip.

3// 280 x 360mm reinforced strip concrete foundation.

4// Passive slab- 3x EPS 100 rigid insulation, DPM, EPS 300 L element.

5// Concrete & recycled plastic aggregate screed flooring.

6// Printed ceiling panels.

7// HVAC ventilation system.

8// 10 x 35mm C profile ceiling clip.

9// Lighting designed by DUS Architects.

10// Electrical wiring modules.

11// D-175mm W- 225mm L4600mm 3D printed structural beam (developed

by Contour Crafting (California)

12// Floor system- 10mm Ridigur fire protection, 15mm floor deck, 45mm floating sub floor, 15mm floor finish.

13// 3D printed wall system, minimum size 450mm x 3100mm.

14// Structurally optimised 3D printed column with poured concrete infill.

15// Structurally optimised 3D printed lintel with poured concrete infill.

16// Integrated PV arrays 17// Case of structurally optimised 3D printed column with poured concrete infill.

18// fixing junction for 3D printed wall elements to structural columns 19// 3D printed infill to wall system. The wave from is due to the need to only have material where it is structurally needed

20// 160mm deep recycled insulation containing shredded plastic from failed prints.

21// DPM 22// Integrated serving pipes, printed within the wall system 23// Integrated electrical modules - plug socket

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Printed & non-printed elements The Solar House

1// Case of structurally optimised 3D printed column with poured concrete infill.

2// Structurally optimised 3D printed lintel with poured concrete infill.

3// Structurally optimised 3D printed column with poured concrete infill.

4// 3D printed wall system, minimum size 450mm x 3100mm.

5// D-175mm W- 225mm L4600mm 3D printed structural beam (developed

by Contour Crafting (California).

6// Lighting designed by DUS Architects.

7// Printed ceiling panels.

8// Concrete & recycled plastic aggregate screed flooring.

9// Integrated serving pipes, printed within the wall system.

10// 160mm deep recycled insulation containing shredded plastic from failed prints.

11// 3D printed infill to wall system. The wave form is due to the need to only have material where it is structurally needed.

12// Fixing junction for 3D printed wall elements to structural columns.

Key Fully 3D printed Printed composite Not printed

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MakerStadâ&#x20AC;&#x2122;s Printed Parts

1

1:10 at A1

2

3 4

5

12

6 7

11 10

9

8

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Printed wall profile Concrete wall 100% infill

Clad steel frame 60% infill

Printed wall 15% infill

Our wall profile uses 85% less material than a typical concrete wall. This translates as savings in your pocket whilst helping to protect the environment!

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MakerStadâ&#x20AC;&#x2122;s Printed Profile

Pr in t

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Pa

th

How much does your house weigh?

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As your entire house will be modeled in our state of the art software, we are able to calculate the weight and therefore cost of your printed elements instantly.

Meaning at StadMaker there are no hidden costs! You just pay for the material you use.

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How much does your house weigh?

(Calculation are for printed facade elements only)

££££

5.3 metric tonnes ££££

4.4 metric tonnes

££££

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4 metric tonnes ££££

2.6 metric tonnes ££££

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Servicing strategy 1// Electrical switch and fuse box.

2// MVHR fresh air ventilation duct.

3// MVHR stale warm

air extraction duct.

4// Electrical wiring fed through floor trusses.

5// Services entrance point. All services enter ever house at a fixed point throughout The 203, The 169, The 101 volumes.

6// Combined ASHP space Heater and

MVHR unit.

7// Printed ceiling panels.

8// Concrete & recycled plastic aggregate screed flooring.

9// Integrated serving pipes, printed within the wall system 10// 160mm deep recycled insulation containing shredded plastic from failed prints.

11// 3D printed infill to wall system. The wave form is due to the need to only have material where it is structurally needed 12// Fixing junction for 3D printed wall elements to structural columns

As covered in Step 1, The Brain is the only room thats position is fixed within your design. This allows for quicker and simpler installation and possible repairs.

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MakerStadâ&#x20AC;&#x2122;s Servicing Strategy

1

2

3

4

7 6 9

The Brain

8

5

5

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Servicing strategy printed to non-printed junction

At StadMaker we have developed a system that allows for traditional appliances, fixtures and fittings to be incorporated into a 3D printed environment.

So if you prefer the feel of porcelain, we have you covered.

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Printed pipe Standard non-printed pipe Printed connection junction

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Pre-customised section 1:20 at A1

450mm default Width

Roof must be inclined to a minimum of 2 째 to allow for rainwater to run off the drainage channel.

Integrated service channels printed into the facade elements.

A channel on the external side of the wall elements collects rain water for harvesting

MVHR unit provides fresh air to the houses whilst removing stale warm air.

Small risers distribute services upwards and then horizontally above the ceiling.

Vertical junction between printed wall panels

The Bra

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MakerStadâ&#x20AC;&#x2122;s Section 1:20 at A1

Concealed guttering must be located on the lowest side of the roof

How will you customise yours?

ain

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Customised section 1:20

at A1

The Solar House

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MakerStadâ&#x20AC;&#x2122;s Section 1:20 at A1

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_Rule Book 163

What Will Your StadMaker House Look Like?

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The Rules are not in place to stifle your creativity, but instead to ensure that a well rounded and deliverable design for your future home is achieved.

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The Primary Rule CUSTOMISATION RULE 00: Customisation freedom is catered for as long as the said customisation does not impact negatively on the final sustainable code rating.

01:

Customisation that aims to improve the sustainable code rating is encouraged and supported.

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The Rules Rule 01: The Plot

Rule 02: Entrance

Customisable Surface

Controlled surface servicing insulation

Rule 03: Wall Zones Structural Element

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External wall consist of 3 key zones. The customisable zone, controlled zone and structural zone. Understanding these zones is the first key step in understanding how customisation takes places within your STADMAKER Home.

The Rules Wall depth

450

Rule 04: Customisation Depth The Standard depth of an external customised surface is 115mm. There is 300mm of additional customisation depth available. Any distance beyond this will extend too far into surrounding land.

The Internal customisable depth is 60mm, however this includes only internal wall finish and does not take into account printed items such as storage and shelves.

115

300

275

60

115

450 Max Cust Depth

Rule 05: Window Location & Size The allowed location of windows are shown in white. No matter what the size of the allowed opening (In this example 3950mm) the maximum span of a single window is limited to 2000mm due to the nature of the construction.

Other than this the shape of a window is not controlled.

3950

2000

Rule 06: Window Location Part 2 Windows are not allowed within either 250mm or 200mm (Volume Choice Dependant) of structural elements. This allows room for servicing to run vertically through the wall system.

250

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The Rules Allowed Window location

Rule 07: Window Location by Orientation The percentage of Window to surface is limited depending of the orientation of a given facade surface. For example, the maximum percentage of opening on a south facing facade is 45% of the total surface. On a north facade this is reduced to 15%. This is to limit unnecessary heat loss and help achieve a code 6 sustainable home.

45% South

30% East // West

15% North

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The Rules Rule 008: Door Locations The allowed locations of external doors are shown in blue. Their positioning along this stretch will depend on your chosen interior layout. This is something your project Architects will work along side you to set out.

Rule 09: Circulation Space

Living Space

Printed Storage Unit

The location of circulation space internally in not governed. What is governed is that circulation must be 1000mm at its narrowest point. This Ensures housing meets the standards set out in Homes for Life.

1000mm

Rule 10:Location of The Brain The location of the Brain is fixed. This allows for a set location for services to be installed on a plot and into a house.

Brain

Rule 11:Location of Wet Services Brain

WC

Kitchens, Toilets and Bathrooms must share a wall with The Brain, or its riser on the above floor. This ensures a sensible and economical distribution of services.

Eat

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The Rules Rule 12:Location of Governed Items Some items such as stair cases will be governed to a set corner of a floor plan.

This may be for a number of reasons.

Although not a set rule we encourage stair cases to be located against the north facing facade, as it is sensible for it to be located areas with a lesser need for natural light.

Rule 13: Roof Angle Roof design requires more work along side a Stadmaker designer. To ensure designs are structurally sound. The main governing rule is that there must be a minimum roof angle of 2째 to ensure a sufficient angle for rain water run off.

Rule 14: Rain Water Collection Rain water collection can be integrated within the roof or even the facade panels, as DUS Architects have done for their house design.

Rain water collection must always be located on the lowest side of the roof.

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The Rules

Rule 15: Printed Junction The junctions between each printed panel must not altered through customisation. Their position and shape must be consistant throughout to ensure a small level of repetition that greatly increases the buildability and speed of the assembly.

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The Rules

Rule 16: Impacting your neighbour Customisation must not negatively impact upon the neighbouring properties.

Rule 17: Inappropriate customisation Indecent customisation is not aloud. Although freedom of expression is encouraged, StadMaker must draw the line at a point to ensure a pleasant living environment for everyone.

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Print Guides Encourage Discouraged

Unsupported Horizontal Surface These surfaces require support material to be printed in order to hold up the unsupported surface. This requires a considerable amount of material that will not be used in the finished item.

Inclined Surface These are encouraged as the material printed on the layer below supports the next layer to be printed meaning no unused support material is required.

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Print Guides

3800 36 00

00 36

As long as it fits we can print it.

And if it doesnâ&#x20AC;&#x2122;t you can split it into multiply files and print it anyway!

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