Hempcrete 3d printer

Texas A&M receives $3.74M for green, 3D-printed hempcrete buildings research

June 17, 2022 By Alyson Chapman

Amy Halbert

Assistant Director of Communications

ahalbert@tamu. edu

979-458-4243

Dr. Petros Sideris will lead the research to develop residential and potential construction designs using hempcrete. | Image: Texas A&M Engineering

A plan from Texas A&M University researchers to 3D print new resilient buildings using hempcrete has the potential to lower the environmental impact of traditional construction methods and make housing more affordable and available.

The project will be funded by a $3.74 million grant from the U.S. Department of Energy Advanced Research Projects Agency-Energy (ARPA-E) Harnessing Emissions into Structures Taking Inputs from the Atmosphere (HESTIA) program.

Dr. Petros Sideris, assistant professor in the Zachry Department of Civil and Environmental Engineering, will lead the project as principal investigator to develop residential and potential commercial construction designs. His team consists of assistant professor Dr. Maria Koliou, department head and professor Dr. Zachary Grasley, and professor Dr. Anand Puppala from the department, and associate professor Dr. Manish Dixit and professor Dr. Wei Yan from the Texas A&M College of Architecture.

Hempcrete is made by mixing hemp powder, fibers or shives with lime and water, creating a lightweight, green building material.

The raw hemp hurds are one component of hempcrete, which is also made of lime, water, hemp powder and fibers. | Image: Getty Images

"While production of conventional construction materials such as concrete requires large amounts of energy and releases large amounts of CO₂ (carbon dioxide), hempcrete is a net carbon-negative material, which can provide major environmental benefits," Sideris said.

Sustainability will be further promoted by designing hempcrete structures more resilient to natural hazards than commonly used lightweight wood frame construction.

"Resilience to natural hazards is intertwined with environmental sustainability because building damage and subsequent repairs due to extreme events such as hurricanes result in major environmental impacts," Sideris said.

Researchers will use 3D printing in this project to create building designs that achieve structural and energy performance to comply with modern design codes. | Image: Courtesy of Petros Sideris

Hempcrete has already been used globally in residential construction and prefabricated modular construction.

"Hempcrete has excellent fire resistance and thermal insulating properties that can reduce heating and cooling energy demands," he said. "It is water-resistant and offers good acoustic properties."

As part of the project, building designs will be printable and created to achieve structural and energy performance that will comply with modern design codes. Sideris said digital designs of printable hempcrete buildings will facilitate adoption by the construction industry.

"The advancements of this project will contribute to the U.S. maintaining its worldwide leadership in advanced construction methods and infrastructure sustainability and resilient technologies," he said.

The funding is part of HESTIA, which prioritizes overcoming barriers associated with carbon-storing buildings, including scarce, expensive and geographically limited building materials. The HESTIA program aims to increase the total amount of carbon stored in buildings to create carbon sinks, which absorb more carbon from the atmosphere than released during construction.

Can 3D printed hempcrete replace traditionally-used concrete?

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Petros Sideris is an Assistant Professor in the Zachry Department of Civil & Environmental Engineering at Texas A&M University. He started looking into construction 3D printing as an alternative to traditional construction more than five years ago, and his research has focused on concrete 3D printed structures and how they perform under service conditions and extreme events such as earthquakes. He has not started researching the potential of 3D printed hempcrete.

Throughout his research in the broad area of concrete structures, Petros Sideris has conducted large-scale structural testing, computational modeling of structures, and modeling at the material level.

When he first heard of construction 3D printing, he was skeptical (considering this was more than five years ago). “I’m not saying that I thought it wouldn’t work. I’m saying that it wasn’t as popular. Interest in this area has been growing almost exponentially since then. And there has been this idea out since the 90s, right. There’s even some work we found online that was performed in the 30s.”

However, nearly a week later, he was sold on the idea. “I felt like there is a lot of potential in terms of automation. And if you look into this in more detail, you’ll see that the construction sector is probably the least automated sector of the economy, not only in the U.S. but worldwide. There’s a huge potential for automation there, and 3D printing was well in this direction. And then it ties in very well with efforts to address some major problems like, for example, the housing issue, the ‘housing crisis,’ as we call it in the U.S., which is also probably a problem in several countries. That’s kind of how I started. I saw value, and then I dived into that,” said Petros Sideris. “And here we are, with several different ideas, some of those relating to concrete and now some more recent ones that relate to more sustainable materials and their applications in actual large-scale construction.”

Assistant Professor Petros Sideris

The big picture idea for Petros Sideris’ research is that there is an increasing need for housing in the U. S. and many countries around the world. In the U.S. alone, it has been recently estimated by the Federal Home Loan Mortgage Corporation (Freddie Mac) that the country needs more than 3.8 million new homes. At the same time, the manual labor force, the construction labor force, is decreasing. Considering this – it is highly unlikely that the current state of construction practices can address these needs.

This is where the need for automation and alternative construction techniques are of value. 3D printing, due to its automation, lights-out, 24/7 manufacturing, requiring minimal personnel, is a near-perfect solution to this problem.

However, using traditional materials in conjunction with this more contemporary technology is not ideal, as concrete, for example, is not a sustainable and environmentally-friendly material.

“Concrete, as you probably know, is not a very environmentally-friendly material. It comes with a lot of carbon emissions. So that’s a big issue. What our project is trying to do is to marry these two ideas. One is construction 3D printing, which I would say is a more environmentally-friendly construction process for two reasons – you do not need to place concrete anywhere else but at the locations where you need it, and you don’t need formwork, which you would usually use just a few times and then throw it away. So these are two major benefits of the process itself. Now we try to marry this process with a sustainable material. That sustainable material is hempcrete. Hemp by itself is a very attractive material to us in construction because it, essentially, has a negative carbon footprint – it sequesters a lot of CO2. What we’re trying to do in this project is print using hempcrete. That’s the big challenge.”

The second challenge is for the team to design structures that are structurally code compliant and also code compliant in terms of energy performance. “So we try to rethink how you design structures using this type of material. We will also be trying to end up with an entire structure that is net carbon negative over its service life. ”

Image source: Petros Sideris

The team will also be looking at the structures’ performance over time. If a structure itself is sustainable, at face value, but needs to be replaced or repaired every few years due to hurricane damage, for example, then it is not truly sustainable. To prove the hypothesis, the team will have to find the harmonious balance between sustainability and resilience – and study how the two affect each other.

In terms of the process of turning the hemp plant into hempcrete, Petros Sideris noted that he is not a materials engineer, and he may not be the best person to explain the process to us, “But what I can tell you is that we’re looking at different parts of the plant. We’re looking at using hemp fibers, and we’re also looking at some more innovative approaches, such as hemp powder, for example. We’re looking at how we can use those materials to get a mix design that would be printable and at the same time environmentally friendly.”

Concerning modifying the hempcrete to be 3D printable – “We have a plan on how to do that. We have thought about different ideas, and we have some specific ideas on how to do it. What we’ve been doing so far, even prior to the formal initiation of this project, is that we have already started talking to producers and seeing what materials we have available, and discussing what we expect we would need. We have also had some preliminary work in those directions. We believe that our approach will address the challenge of having a 3D printable hempcrete mix design.”

As part of the research project, the team will explore the availability and accessibility of the quantities of hemp needed for this construction technique to be viable and sustainable. For now, “what I can tell is that in the United States, we know that there is a lot of interest in growing hemp and supporting this idea. Studies have already shown there is a lot of benefit to growing hemp for construction applications, so we expect that there will be no problem. The project will investigate that, though, and come up with more specific answers to those questions because, at this point, is an expectation that we have. It looks like there are lots of producers ready to jump on this idea, but we will have a more definitive answer once we do a more specific analysis,” said Petros Sideris.

When probed as to what Petros Sideris thought of the potential future for hempcrete, he had this to say:

“That’s very difficult to predict. I guess at this point we can only speculate in terms of the market. But if we try to just think in a reasonable manner, what we know is that the present construction practices are unsustainable – for example, building this massive number of homes using conventional concrete, and for this reason, it’s reasonable to expect that we cannot keep them for a long time. So, at the end of the day, to address these huge demands, you need to find a sustainable way to do it. In that sense, our project is in the right direction, and you can tell that a structure that addresses both sustainability and resilience is kind of the answer, or a potential answer, to the challenge that we’ve been facing, I would say as a nation [USA], but also worldwide. ”

The formal research is expected to start this September, after the team has finalized the details with the Department of Energy, with the earliest possible results being published two years from now.

Will the "hemp" 3D printer see the light of day?

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More than three decades have passed since the introduction of the first 3D printer (1986). During this time, experts have made a lot of efforts to improve it. They worked:

on image accuracy;
print speed;
strength;
size reduction.

Over the years, the search has been for sustainable printing materials that could expand the range of 3D products. What do modern 3D printers print?

The materials are quite diverse: various types of plastic, metal, food substances, building materials and even living cells.

Every day, scientists try to discover more and more new materials with which to create three-dimensional images. There are also quite strange ideas. nine0011

How about cannabis?

Yes, just imagine! Sometimes the ideas of specialists are simply striking in their originality. The authors of this unusual idea were the employees of the Australian company Mirreco. According to experts, quite a variety of products can be obtained from hemp. And all thanks to the outstanding properties of the plant, such as:

low cost;
intensive growth;
environmental friendliness;
excellent working qualities;
resistance to the greenhouse effect; nine0004
carbon dioxide destruction.

In fact, they started talking about cannabis for a reason. The fact is that Mirreco is engaged in the production of mobile plants that help in the processing of technical hemp, as well as its separation into seeds, fibers and fire. Why do they do it? It's simple - these components serve as raw materials for the manufacture of various goods and materials. The bonfire is used in the manufacture of paper, the fibers for fabrics, and the seeds for paints and lubricants. But what were the Mirreco employees up to? nine0011

You won't believe your ears! They decided to grind the stems and leaves of the plant into biomass in order to build real hemp houses from the resulting material!

Why choose hemp

As Mirreco assured, hemp material has many advantages:

excellent thermal insulation properties;
easy to manufacture.

Hemp products have such qualities as:

durability; nine0004
anti-allergenic;
antiseptic;
ability to breathe;
comfort temperature maintenance.

Experts say that a hemp house can be erected in just a couple of weeks! And it will already be equipped with communications and modern technologies for generating electricity from sunlight.

What good fellows those who try to invent something, somehow make life easier and diversify! Everyone should follow their example. nine0011

In this regard, we are not at all pleased with the developers of conventional laser printers. If they thought about how to create new consumables, cheaper and more modern. After all, such devices, like many years ago, work with expensive cartridges.

Although in the case of laser printers there is a more acceptable way out of the situation, which will reduce the cost of printing. This is refilling already used cartridges. If you stick to this method, you can save a lot by paying only for the toner and the work of the master. And it is much cheaper than buying originals. nine0011

What about hemp houses? At the moment, it is not known when their mass construction will begin. However, the development of the installation, which was mentioned earlier, has been completed. And many more such stations will be created. And all in order to use them on plantations.

Let's wish the specialists good luck, remain as extraordinary, believe in their work and look for new ways to solve the tasks!

Marijuana in the blood? No, hemp has now settled in the 3D printer

Three-dimensional printing is becoming more and more firmly established in the life of mankind, today this innovative technology is actively used not only in the world of scientific developments, but also “by leaps and bounds” breaks into various fields of activity. You can even buy a 3D printer for your home, it has been on sale for a long time. However, such devices require "consumables" - raw materials from which various objects are printed; relatively recently, a natural base was developed to replace polymer components, which will be discussed in this article. nine0011

How did it all begin?

In 1986, the American scientist-engineer Chuck Hull invented a stereo lithography machine, which is recognized as the forefather of the modern 3D printer. And in 1988. developer Scott Crump introduced the 3D modeling method. After 8 years, 3D Systems released the first prototype in history (Actua 2100), which performs the design of three-dimensional objects.

Yes, it required serious improvements, and therefore decades were spent on its improvement. Scientists have invested a lot of effort to ensure that the modernized models produce high quality prints, since 2008 the raw material platform has also expanded significantly. The standard used earlier ABS plastic began to be replaced by other materials, and sometimes quite unexpected ones, for example, chocolate, biocomposites, sandstone and even hemp. nine0011

Advanced 3D Designs

Today, 3D design finds its application in many areas, some of which, frankly, surprise and amaze the inexperienced layman.

1. Human organ transplantation and prosthetics.

This direction has been developing vigorously since 2013, as the need for bioimplants - analogues of human organs that can save a lot of lives, or at least alleviate them, is only growing. Unfortunately, the short lifespan of the analog organ remains a pressing issue here, so researchers still have work to do. nine0011

2. Manufacture of technical accessories and components.

Based on the elastic, non-deformable NinjaFlex material and the 3D engineering system in England, the Fenner Drives plant has launched the production of polymer components for various kinds of equipment and electronics: buttons, covers, etc.

3. Making clothes.

Many designers were also inspired by the idea of creating clothing and decor elements using 3D modeling after the successful project of the Victoria's Secret brand. In 2013, he presented the Snow Queen costume to the general public, the main elements of which were made using innovative technology. Designers emphasize the exclusivity of this method, which allows 3D scanning to fit, for example, a dress, to the individual shape of the figure. nine0011

4. Construction of buildings.

In the United Arab Emirates, a project was launched to create a one-story office center with a total area of about 180 sq.m. using a six-meter 3D printer. This technology, according to experts, will reduce time costs by 75% and labor costs by 2 times. By the way, the internal interior filling is also planned to be produced according to the above scheme.

And the European Space Agency ("European Space Agency") proposed to build a base on the moon, erecting buildings using the 3D design method. According to their calculations, the “construction” of 1 complex will take an average of 7 days. nine0011

5. Auto simulation.

The first printed car was released in 2010, and in 2013. on its basis, the concern "Korecologic" released a new improved model "Urbee 2". And this unique car of its kind can go. Its maximum speed is 112 km/h.

6. Making weapons.

Defense Distributed holding in the United States of America in 2013. The first printed pistol with the loud name "Liberator" ("Liberator") was released, only one part of which out of all sixteen was made of metal. nine0011

Hemp as raw material for 3D printing

The possibilities of using the innovative 3D printing method, as time has shown, are almost limitless. Every year new sources of raw materials appear in this area, which not only expand the boundaries of what is permissible, but also allow us to improve existing developments. Cannabis is one of the most recent bio-resources. What has changed with its appearance in the 3D industry?

nine0011

3D technology to help canna growers

Slovenia has developed a 3D printer capable of revolutionizing traditional crop production. It “prints” with a specially prepared mixture of soil and seeds, distributing the latter within strictly specified parameters. This innovation will greatly simplify the process of breeding new varieties of marijuana.

In addition, in the USA, with the assistance of 3Dponics, a leader in the hydroponic agricultural industry, a 3D printing machine was made that allows you to create unique pots for growing cannabis. These pots, consisting of three elements - the tub itself, the stand and the lid, are an artificial soilless environment enriched with essential minerals. So the consumer (amateur gardener or farmer) can only ensure regular watering of the plant. nine0011

"Miracle of technology" in medicine

Medicinal marijuana has already been legalized in many countries around the world, it is prescribed for the treatment of a number of diseases, and for pharmacists the issue of the correct dosing of drugs is acute.

Two developers from America, Ashley Herr and Paige Colin, solved this problem, based on the achievements of the 3D industry. Hemp oil, which has become the main ingredient, they dry and mix with a water-soluble biopolymer and other inert pharmacological substances. Then the resulting mass is forced through the forming tool, turning into edible fibers. This allows you to achieve the necessary and precise ratio of the active substances of cannabis - cannabinoids and terpenoids. And also to resolve the issue of their dosage. nine0011

Ashley Herr and Paige Colin patented their invention under the name "Potent Rope", which literally translates as "powerful, potent or effective rope." Talking name, whatever one may say!

"Potent Rope" cannot be classified as food products, such as hemp cookies, sweets, marmalade, etc., as it contains a pharmacological polymer. It is clearly a drug, which means that it can be freely sold throughout the United States, while in many of them the usual use of cannabis products is prohibited by law. However, athletes are afraid to take it, as the discovery of marijuana in the blood may lead to disqualification. nine0011

Hemp Biofilament

The main raw material for FDM printing, layer-by-layer fusing modeling, is a thermoplastic eco-friendly bio-resource - polylactide. However, the developers of the Brooklyn-based design studio MatterLab announced the creation of new natural and biodegradable sources. These are composite biofilaments (filamentous formations) made of marijuana and tagua nuts, capable of competing for the "palm" with the reigning leader. According to the data provided, only 20% of this material will consist of traditional polylactide, the remaining 80% will be derivatives of technical cannabis and tagua palm fruits. nine0011

In parallel with American engineers, the Italian company Kanèsis announced a similar know-how to the world. The leaders of Kanèsis, Giovanni Milazzo and Antonio Caruso, have already patented the composition of a 100% biodegradable 3D modeling raw material, the fundamental component of which is industrial hemp. The development was given a name - "HempBioPlastic".

Giovanni Milazzo and Antonio Caruso note the special thermoplasticity of plant fibers, similar to propylene. But unlike the latter, biocomposite cannabis is 20% lighter and 30% stronger, as well as more environmentally friendly and cheaper than its counterpart. Contracts have already been concluded, according to which HempBioPlastica will be used to produce bottles, disposable tableware and other products. nine0011

3D printing:

The wave of legalization of medicinal cannabis stirred up not only the raw material segment of the market, but also made many entrepreneurs and researchers puzzled by the invention of new products in the field of direct use of the product itself.

Design smoking pipes

American brothers Al and Saul Jacobs founded the company "Printabowl" and set up the production of exclusive designer pipes for smoking cannabis, which are created on their own, once home, 3D Printer. Any model is rather a work of art, they are least of all similar to classic smoking devices - actually traditional pipes, bongs or pipes. nine0011

The brothers are engaged in the development of each model range independently. After the design work, blanks are directly printed on a 3D printer, into which ceramics are poured. The hardened product is baked, after cooling it is polished and baked again. The result is a durable, glossy and authentic smoking ceramic product.

Medical marijuana inhaler

The Israeli holding "Syge Medical Ltd" has released two samples of a medical compact inhaler on a 3D technology platform. The development of these devices was carried out over a long four years, and yet engineers and doctors managed to achieve the necessary balance of required parameters, such as reliability, accuracy, thermal stability and biocompatibility of the components. nine0011

Inhalers allow you to use a medicinal product based on medicinal cannabis, correctly calculating the dosage of inhalation. This makes it possible for patients to avoid the intoxicating side effect and not to think about how long cannabis stays in the blood and urine, and how this will affect their health later.