1. USC Viterbi School of Engineering. Automated Construction by Contour Crafting Automated Construction by Contour Crafting Behrokh Khoshnevis University of Southern California

2. USC Viterbi School of Engineering. Fabrication Processes  Formative (pressing, forging, bending,..)  Subtractive (milling, turning, chiseling, sawing, stamping..)  Additive  Casting (requiring mold)  Traditional Layered Fabrication (only in manual construction)  Modern Layered Fabrication (SFF or RP) Technologies

3. USC Viterbi School of Engineering. Commercialized RP Technologies

4. USC Viterbi School of Engineering. SIS – Selective Inhibition Sintering

5. USC Viterbi School of Engineering.

6. USC Viterbi School of Engineering. MPM – Moldless Powder Metallurgy

7. USC Viterbi School of Engineering.

8. USC Viterbi School of Engineering. Limitations of current SFF methods Slow speed Not scalable Limited choice of materials Impossible to embed other objects

9. USC Viterbi School of Engineering. What is Contour Crafting? Material feed barrel Nozzle Side trowel Side trowel control mechanism Top trowel CC is a layered fabrication method which combines ancient surface forming concepts with modern robotics technology

10. USC Viterbi School of Engineering. A Scalable Process Ideal for Large Objects Layer Height: Several Centimeters Surface Quality: About 2 microns

11. USC Viterbi School of Engineering. A CC machine for thermoplastics

12. USC Viterbi School of Engineering. Nozzle Assemblies

13. USC Viterbi School of Engineering. Plastic Parts

14. USC Viterbi School of Engineering. CC Machine for Ceramics

15. USC Viterbi School of Engineering.

16. USC Viterbi School of Engineering. Process & Machine Design Research Comparison of the flow pattern with the simulation result and the actual process on the near optimal conditions: side views with a square orifice (top pictures), and side views with an elliptical orifice (bottom pictures)

17. USC Viterbi School of Engineering. Movable Side Trowel Cylinder Connector Bevel gear Nozzle Side trowel mechanism of movable side trowel

18. USC Viterbi School of Engineering. Building Various Surface Slopes

19. USC Viterbi School of Engineering. 2.5D and 3D Objects

20. USC Viterbi School of Engineering. Slant Wall Fabrication