3D-Printed Habitat Mid-term Webinar Challenge September 05 ...Mid-term Webinar September 05, 2018...
Transcript of 3D-Printed Habitat Mid-term Webinar Challenge September 05 ...Mid-term Webinar September 05, 2018...
3D-Printed Habitat
Challenge
Phase 3Mid-term Webinar
September 05, 2018
• Welcome/Sponsors and Supporters
• 3D Printed Habitat Challenge – Status Update
• 3D-Printed Habitat Challenge – Levels Review
• Judging Comments
• Construction Level 2 (Hydrostatic Testing)
• Virtual Construction Level 2 (100% Design)
• Construction Level 3 – (Subscale Habitat Competition)
• Q&A
Webinar Agenda
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Welcome
Lex Akers – Bradley University –
Dean of the College of
Engineering
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Allied
Organization
Sponsors
Team Agreement
Competitor
TeamsMemo of Understanding (MOU)
Space Act Agreement
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3D-Printed Habitat Challenge
Status Update
Tony Kim - NASA
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Significance of the 3D Printed Habitat Challenge
“One of our primary goals for NASA is to Enable Humans to Live and Explore on
Planetary Surfaces. This competition will help us to answer fundamental
questions and possibly to develop capability needed to deliver on that ambition.”
"In-space manufacturing technologies such as the 3D-Printed Habitat technology
are some of NASA's greatest challenges."
“About a month ago I attended a National Science Foundation sponsored
Workshop on Additive Manufacturing for Civil Infrastructure Design and
Construction. This was a world-class international event with a total of 171 people
that attended the workshop, with 17 from industry, 23 from government, and 131
from academia. This particular competition was mentioned many times because
of the excitement it has generated. The world is watching you!”
John Vickers
NASA Space Technology Mission Directorate Principal Technologist
09/22/2017
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Penn State
SEArch+/
Apis Cor
Northwestern
Imagine
Robots
FormForge
PosTech
Colorado
School
of MinesCalTech
ALPHA
Grow
Mars
Zopherus
Mars
Incubator
Kahn-
Yates
Scrappy
X-Arc
AI
SpaceFactory
Hassell&
EOC
BokettoIndia
ThebertonAustralia
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Media Coverage included clips and videos
appearing in:
Architectural Digest Popular Science
Popular Mechanics Wired
Gizmodo Huffington Post
CNET Wall Street Journal
Gizmag Make
Forbes Yahoo News
More than 1,400 traditional media hits
3DPH Challenge received more than half of the total
hits to our program websites in 2015, ~55K.
The program continues to receive requests from
media outlets asking for information, images,
interviews, etc., almost weekly.
Phase 1: Design | Media Traditional products: media advisory, press
release, web features
Social: A huge push on social media was made
to increase registration, because of which we
gathered the largest pool of applicants CCP had
ever had, at the time.
Outreach: CCP used stage time and an exhibit
space at the NYC Maker Faire to promote the
challenge and to award the Phase 1 checks.
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The in-person P2:L3 competition was streamed live by NASA 360, as well as captured on the agency’s Snapchat and Instagram accounts, in addition to CCP’s own social channels. Video Views: 404,600Clicks/Actions/Engagement: 64,000Reactions/Comments/Shares: 20,860People Reached / Impressions: 3,263,500
SNAPCHAT – NASA HQ AccountFirst Snap: 203,000
Last Snap: 101,000
INSTAGRAM – NASA HQ AccountFirst Slide: 2,031,851
Last Slide: 591,000
Phase 2: Structural Member | Media
Phase 2 received 374
traditional media hits.
Media Coverage included clips
and videos appearing in:
TechCrunch
Peoria Star Journal
Construction Equipment Guide
Aviation Week
Dallas Morning News
Consumer Electronics
Rocket News 10
3DPH Phase 3 Media Metrics
• 160 media hits, including: PopSci,
USA Today, CNET, MSN, Yahoo,
Forbes, Fox, Engadget, TechCrunch,
Maxim, Esquire, Daily Mail UK, and
ArchDaily.
• 15+ media queries, with more
coming in daily, including NBC
Universal, two TV news interviews,
and journalists in Switzerland, Peru,
Mexico, Singapore, Vietnam,
Germany and others.
• The Top 5 team videos shared on
YouTube have received more than a
half-million views since they were
posted and linked to inside the press
release.
• A single tweet from the @NASA
Twitter account linking to the feature
received 4,800 likes, 1,200 retweets
and 210 comments
• Potential audience from traditional
media of more than 170 million
viewers
• National Geographic published 3
articles mentioning 3DPH in a special
edition Mars issue (July 2018)
• Centennial Challenges video on the
3D Printed Habitat challenge was the
3rd highest watched Marshall
YouTube video in the past three years
with 305,351 views, 110 comments
and 1,339 likes.
Spike in news
coverage after prize
award is
made public
3D-Printed Habitat Challenge
Levels Review
Mike Grichnik - Caterpillar
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Phase 1 – Design - $50,000 prize purse
Phase 2 – Structural Member - $1,100,000
prize purse
Phase 3 – On-Site Habitat Challenge - $2,000,000 prize
purse!!!
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NASA’S 3D-Printed Habitat Challenge – Phase 3
• Develop a full scale habitat (92.9 m2 (1000 ft2)) design using
Building Information Modeling (BIM) software and create an
autonomous 3D-Printing system to construct that habitat at 1:3
scale using indigenous and recyclable materials at the head-to-
head competition in April/May 2019
• Teams competing in the Construction Levels are required to
participate in Virtual Construction Levels;
• Teams can choose to participate in the two Virtual Construction
levels only.
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Virtual Construction (BIM)
Level 1 Virtual Construction – 60%
Design Development
Level 2 Virtual Construction – 100% Design Development
Sub-Scale Construction
Level 1 – Foundation
Level 2 – Hydrostatic Testing
Level 3 – Head to Head 1:3 Subscale Habitat
(10.32m2 = 111 ft2)
Phase 3 Competition Levels (Summary)
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NASA’S 3D-Printed Habitat Challenge – Phase 3
Virtual Construction Levels - $200,000 prize purse overall
• Virtual Construction Level 1 – 60% Design
• MEP & ECLSS Design (LOD 100)
• Structure & Pressure Retaining Walls/Components (LOD 300)
• Virtual Construction Level 2 – 100% Design
• MEP & ECLSS Design (LOD 200)
• Structure & Pressure Retaining Walls/Components (LOD 400)
❖ MEP – Mechanical/Electrical/Plumbing
❖ ECLSS – Environmental Control Life Support System
❖ LOD – Level of Design
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NASA’S 3D-Printed Habitat Challenge – Phase 3
Construction Levels - $1,800,000 prize purse overall
• Construction Level 1 – Foundation
• Print a foundation within required specifications (2m x 3m with 100 mm slab
thickness)
• Complete other sample prints and evaluations (including slab durability, material
strength and durability)
• Construction Level 2 – Hydrostatic Testing
• Print a foundation and a cylindrical wall with penetrations to demonstrate leak
tightness
• Complete other sample prints and evaluations (including material strength and
durability)
• Construction Level 3 – 1:3 Scale Habitat Printing
• Print a 1:3 scale simplified version of team’s habitat design at the head-to-head
event
• Complete other sample prints and evaluations (smoke test for leakage, a
projectile drop test for robustness, a crush test for ultimate strength and material
strength and durability tests)
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NASA’S 3D-Printed Habitat Challenge – Timeline
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We
are
here
“Late Entry” On-Ramps for the Future Competition Levels
• Construction Level 2 – Hydrostatic Testing - late qualification deadline is Nov. 7, 2018
• Complete the registration requirements
• Complete and submit the mix design, physical samples and test results from the C39 and
C666 tests, and a video clip documenting team’s printing process for assessment by
Bradley University
• Physical samples due by November 21, 2018
• Virtual Construction (BIM) Level 2 – 100% Design
• Complete the registration requirements and submit by the January 16, 2019 deadline
• Construction Level 3 – Subscale Habitat Competition - late qualification deadline is April 1, 2018
• Invitation only – up to eight teams
• Priority is to teams with the best results through the hydrostatic test
• If there are open spots, completing registration requirements and submitting a proposal
along with a BIM model developed to LOD 400 for the structural and pressure retaining
elements and to LOD 200 for MEP & ECLSS is required to be considered – requests will be
evaluated on a rolling basis
• Teams must also complete and submit the mix design, physical samples and test results
from the C39 and C666 tests, and a video clip documenting team’s printing process for
assessment by Bradley University
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Judges’ Feedback
Pete Carrato – Bechtel
Cory Brugger – HKS
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Level 1 Judges’ Information
• BIM and Virtual Construction Judges
• 14 Judges: Majority are practicing Architects
• Almost half of the judges are “Space Architects”
• The balance work for major firms designing iconic structures
around the world
• Specialists in Fabrication and Technology
• Head architectural judge nominated by AIA Headquarters
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Entries to Level 1
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• Virtual Construction (BIM) Level 1 - 60% Design
• 17 Teams submitted complete on time entries
• 100% of the available $100,000.00 prize money awarded!
Virtual Construction Level 1 Top Ten
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• Level 1 - Virtual Construction
• Great value in having a “Space Architect” on the review of each
project
• Process for providing comments on Virtual/BIM needs improvement
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Lessons Learned
Construction Level 1 Judges’ Information
• Construction and 3D Printing Judges
• 13 Judges all degreed engineers (more than half with PhD)
• Most participated in Phase 2
• University Professors
• Fellows of the American Concrete Institute
• Researchers in 3D Concrete Printing
• Concrete Material Specialists
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Entries to Construction Level 1
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• Construction Level 1 – Foundation Test Competition
• 3 Teams entered
• Only 30% of the available $400,000.00 prize money awarded
Construction Level 1 Top Three
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• General:
• Website organization improved
• Team agreement process improved
• Construction Level 1 - 3D Printing
• Teams should ensure that videos submitted only show safe work
practice
• Team summaries of “interventions” helped with judging
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Lessons Learned
Construction Level 2
(Hydrostatic Test)
Tracie Prater – NASA
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Construction Level 2: Hydrostatic Test
• Additively construct a habitat element (reduced-scale) and subject it to
hydrostatic testing
• Print foundation slab on 100 mm sub-base of #57 stone
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• Illustration of wall penetration elements
• No restrictions on team design of these elements provided they
have the required inner diameter and are less than 300 mm long
• Autonomy score based on number and duration of interventions
• Verified based on team-submitted video recording and data log
Construction Level 2: Hydrostatic Test
• Quality evaluation based on principles from ACI 117
• Accuracy of penetration locations (horizontal and vertical) and
alignment
• Measure inner diameter
• Bonus points awarded for roof
• Hydrostatic test
• Fill habitat element at rate of at least 10 L/min to a depth of 500 mm
• Filling device should not extend below 1.25 m depth
• Record (video and accompanying measurement) of leakage
over 15 minute period:
• after reaching a depth of 500 mm
• after reaching a depth of 1.25 m
• Teams can choose to pre-soak habitat element for up to 24 hours
prior to test (but must submit a video of this entire period)
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Construction Level 2: Hydrostatic Test
• Focus is on creation of construction materials from indigenous
materials and mission waste (polymer recyclables which would
otherwise be “nuisance” materials)
• As in phase II, a sliding materials scale rates construction material
selection based on relevance to planetary missions– Teams are no longer penalized for use of imported materials (those that would be
transported from earth specifically for construction purposes) as they were in phase II,
but indigenous materials are scored higher than nonindigenous materials on the sliding
scale
• No penalty for water
• Material feedstock must be a blend suitable for the competition (see FAQ 3.12)
– Polymer scale is based on frequency of use of polymeric materials in packaging for the
International Space Station (ISS)
– Aggregate scale is based on relative availability of materials on the planetary surface
Materials
Basalt, considered an indigenous material, is
rated highly on the sliding scale for habitat
construction materials
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Materials
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Materials
3DP Factor calculated based on weighted average
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Materials scoring
The material mix will be assigned a score by summing the products of the 3DP
factor of each material and the amount of that material (by %weight) present in
the formulation.
Video and documentation evidence of the material selections and mixing
process will be required for the judges to be able to validate the mix and award
the appropriate points.
For phase III, a maximum of 100 of 1100 points at each construction level will
be allocated to material selection.
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• Additional materials testing is required only if
material mix has changed since previous submission
– Teams must submit information on new material
mix (constituent materials and percentages by
weight) sufficient to assign a new 3DP factor
– Durability testing of specimens (freeze/thaw test
per ASTM C666) from certified test lab
• This test takes 2-3 weeks to run.
• Scores assigned based on reported
durability factor
– Compression test per ASTM C39
• If materials are unchanged from the previous level’s
formulation (and the previous level’s formulation was
deemed acceptable by the judges), they can carry
over to this level
Image credit: CTRE, Iowa State
University
Construction Level 2: Hydrostatic Test
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– Autonomy in printing (based on video submission and data log): 225 points
– Autonomy in penetration placement and sealing (based on video submission and
data log): 225 points
– Quality: 100 points
• 80 points for positioning the penetrations
– +/-25 mm for position
– +/- 3 degrees for alignment
• 20 points for ID accuracy (within +/- 25 mm)
– Material selection of feedstock blend: 100 points
– Hydrostatic test: 125 points based on performance (leak rate at 1.25 m and 500
mm fill levels)
– Material durability: 75 points
– Compressive strength: 50 points
– Documentation: 100 points
– Roof (bonus): 100 points
• Is the roof present and practical?
Construction Level 2: Hydrostatic Test - Scoring
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✓ Summary of changes in printing process and approach since prior level (captured in
written report)
✓ Document material mix for level 3 and calculate 3DP factor
✓ can indicate that material formulation is unchanged
✓ If changed, certified test lab must submit results of freeze/thaw testing of three
samples and compression testing of one sample to Bradley University
✓ Test samples must also be sent to Bradley University (compression sampl
post-test, durability specimen post-test, and core sample
✓ If changed, submit SDS for material constituents not included in prior level’s
material formulation
✓ If changed, provide documentation of any changes to the mixing process
✓ Documentation of leak test, penetration placement, penetration alignment, and inner
diameter measurement
✓ Video (must also include pre-soak if used)
✓ Data log
✓ Measurements
✓ Discussion of roof design if team exercises this option (part of written report)
✓ Autonomous operation assessment (part of written report) –note number, nature,
and durations of remote and human interventions during printing and penetration
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Construction Level 2: Hydrostatic Test: Submission
Prizes for Construction Level 2
• The top 8 teams may receive a cash prize. Non
US teams are not eligible for a cash award but
will be recognized for their position in the
competition.
• A maximum of $600,000 is available.
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Virtual Construction Level 2
(100% Design)
Cory Brugger – HKS
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Phase 3 Virtual Construction Level 2Construction Documentation (100% Design Complete) Level
• Model review sessions will be evaluating Completeness of Model, BIM Use
functionality, Aesthetic Representation, Realism of 4D Model
• (3D BIM) Habitat Modeling: It is the metadata integrated model and design review
process used to depict an accurate representation of physical conditions,
printing environment, and assets of facility.
• Optional (4D BIM) Construction Sequencing
• Optional (4D BIM) Equipment Flow
• Optional (4D BIM) Virtual Mockup
• 100% model review the MEP and ECLSS shall be at LOD 200 and the
structural pressure retaining components shall be at LOD 400.
• Level of Development shall be judged based on the publicly available guide
lines provided by the BIM Forum http://bimforum.org/lod/ .
• Submission must be provided to Bradley by January 16, 2019
• 3 teams with highest scores awarded prize proportional to score for total amount
of up to $100k
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Judging Categories for Virtual Construction
Level 2 – 100% Model Review
• BIM Completeness: 250 maximum points
• Functionality of Design: 500 maximum points
• Aesthetics : 250 maximum points
• Bonus:
– 4D Model Realism : 200 maximum points
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3D PRINTED HABITAT:
MINIMUM PROGRAM REQUIREMENTS
• 1000 ft2 (~93 m2) of livable space
• Three 46 ft3 (~4.3 m2) ECLSS spaces (environmental
control & life support systems)
• Structural and MEP layout
• Exterior wall penetration
• Functional space planning for 4 astronauts for one year
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Prizes for Virtual Construction
Level 2
• The top 3 teams may receive a cash prize. Non
US teams are not eligible for a cash award but
will be recognized for their position in the
competition.
• A maximum of $100,000 is available.
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Construction Level 3 – Subscale
Habitat Competition
Mike Grichnik – Caterpillar
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Subscale Habitat Competition
• Face to face competition - invitation only
• Limited to no more than eight teams
• $800,000 in prize money available with a
$500,000 top prize!
• More than just printing a 1/3 scale habitat –
requires significant work by the teams leading
up to the actual event
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Caution for Teams in the
Full Competition
The 1/3 scale model of the habitat must be printed
in a 4.5 meter by 4.5 meter area at the head to
head competition.
Total time allocated to printing activities is 30 hours
over three days
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“Pre-work” to Consider
• Optional pre-printed components per rule 8.2.11
• Material mix and durability test results
• Three bending test samples per rule 8.9 printed before
the competition and brought for testing
• Documentation for judge review per rule 8.11
• A BIM model with structural and pressure retaining
elements at LOD 400 and to LOD 200 for MEP & ECLSS
which corresponds to the structure that will be printed at
the event submitted along with the proposal defined in
rule 9.2.
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Facility Overview• Peoria, IL – 2.5
hours SW from
Chicago
• Metro area
population –
375,000
• Home of Bradley
University and
Caterpillar
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• 720 acres for
training and
demonstrations
• 150,000 square
feet of arena under
roof (2)
• First demonstration
– 1971
• 20,000 visitors
hosted annually
Facility Overview
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• Printing and testing will be in indoor
arena
– Compacted soil floor
– Arena is ventilated but not air
conditioned
– Power provided based on requests (60
Hz)
• Printing equipment and component
materials should be shipped in
weatherproof containers
• Event is open to the press and to select
members of the public
Facility Overview
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• April 22-26 – team shipments of material can be received at the
facility (weatherproof containers)
• April 29-30 – teams will have two eight hour sessions to set up,
prep, and test printers before competition
• May 1-3 – teams will have three ten hour sessions to print their
habitat with an additional 30 minutes of startup/cleanup time at the
beginning/end of day
• Friday, May 3 – Strength testing of beams per rule 8.10
• Saturday, May 4 – final evaluation of printed habitats via rules 8.4,
8.6, 8.7, and 8.8; deconstruction and removal of printers from arena
Tentative Timeline
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Questions and Answers
www.Bradley.edu/challenge
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