Funding for Two Projects Aims to Develop More Sustainable Methods and Manufacture Products in Pennsylvania
In Pennsylvania, the housing crisis and the environmental impacts of debris generated in the construction sector persist, and two projects led by Penn State Stuckeman School architecture professors seek to address these challenges while bolstering the manufacturing industry in the state. The projects, funded through the Pennsylvania Department of Community and Economic Development’s Manufacturing PA Innovation Program, aim to develop new methods to improve the manufacturing industry while also utilizing the state’s skilled workforce to achieve the full economic potential for good well-paying manufacturing jobs. Two projects are currently underway, both led by researchers from the Stuckeman Center for Design Computing (SCDC). The first project, titled “Automated Reinforcement of In-place 3D Printing of Spanning Structures,” is being led by José Duarte, who is the principal investigator (PI) on the project. This project focuses on developing technologies for 3D printing affordable housing out of concrete with researchers from the College of Engineering in the Additive Construction Lab (AddConLab). ### Benefits of 3D Printing in Construction
3D printing in construction offers several benefits, including:
• Reduced waste: 3D printing can reduce construction waste, as it uses minimal materials and produces zero waste. • Increased efficiency: 3D printing can increase efficiency, as it automates the construction process and can work 24/7. • Cost-effectiveness: 3D printing can reduce construction costs, as it uses fewer materials and can build structures faster. • Improved quality: 3D printing can improve the quality of construction, as it allows for the creation of complex structures and details that cannot be achieved with traditional building methods. The “Automated Reinforcement of In-place 3D Printing of Spanning Structures” project aims to refine the cable-entraining mechanism and expand its application to reinforced walls, enhancing structural strength and broadening its use. ### Cable-Entraining Mechanism
For his master’s thesis, Ali Baghi developed a system for embedding cables within 3D-printed concrete filaments, enabling the construction of horizontal slabs and complex roof structures. This system has the potential to enable the construction of two-story houses. The team’s manufacturing partner for the grant is X-Hab 3D, a startup company located in State College that was founded by several members from the AddConLab team at Penn State. #### Collaborators and Expertise
The team’s collaborators include:
| **Collaborator** | **Role** | **Expertise** |
| — | — | — |
| Ali Baghi | Co-PI | Systems approach, systems design |
| Shadi Nazarian | Co-supervisor | Systems design |
| Sven Bilén | Co-PI | Robotic concrete printing systems |
| Nathan Brown | Co-PI | Finite element analysis |
| Sanjay Joshi | Co-PI | Additive manufacturing, process planning and control systems |
#### Project Goals
The final goal of the project is to enable the complete 3D printing of homes, including foundations, walls, slabs, and roofs. ### Second Project: Characterization of Mycelium-based Composites Cultivated Using Spent Substrate
The second project, “Characterization of Mycelium-based Composites Cultivated Using Spent Substrate,” aims to develop sustainable building materials using mycelium, the root of mushrooms. The goal of this project is to create sustainable building materials that can replace traditional materials made from petroleum and other non-renewable resources. #### Benefits of Mycelium-based Composites
Mycelium-based composites offer several benefits, including:
• Sustainability: Mycelium-based composites are biodegradable and can be made from waste materials. • Low carbon footprint: Mycelium-based composites have a lower carbon footprint compared to traditional materials. • Durability: Mycelium-based composites are durable and can last for a long time. #### Collaboration
The project is led by Benay Gürsoy, who is joined by co-PI John Pecchia and several undergraduate and graduate students. The team has partnered with Phillips Mushroom Farm, the largest specialty mushroom grower in Pennsylvania, to use the waste produced from growing mushrooms that the farm discards, known as “spent substrate,” to cultivate mycelium-based composites. #### Project Goals
The team will run tests to characterize the composites’ mechanical properties, insulative properties, and other characteristics. The goal of the project is to provide Pennsylvania mushroom farms with alternative ways to use their facilities and add value to their by-products. #### Impact
This project represents a partnership between the Pennsylvania mushroom industry and researchers at Penn State. The collaboration aims to develop sustainable approaches to using spent mushroom substrate, reducing waste, and creating biodegradable building materials. ### Conclusion
The two projects led by Penn State researchers aim to revolutionize the construction industry with new technologies. The “Automated Reinforcement of In-place 3D Printing of Spanning Structures” project focuses on developing technologies for 3D printing affordable housing, while the “Characterization of Mycelium-based Composites Cultivated Using Spent Substrate” project aims to develop sustainable building materials using mycelium. Both projects have the potential to improve the manufacturing industry and create sustainable products in Pennsylvania.
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