Freeform Construction: Mega-scale Rapid Manufacturing for construction

The utilisation of automation technology and processes control found in the automotive and aerospace industries is not paralleled in modern day construction. The industry also struggles to improve health and safety issues and still uses traditional methods of procurement. These problems are compounded by the diminishing skills in the labour force. Methods of production must change if these issues are to be resolved. Rapid Manufacturing is a family of digitally controlled additive processes that have the potential to impact on construction processes. This paper outlines some of the major issues facing construction technology and gives examples of the use of large scale Digital Fabrication in the industry. The term ‘Freeform Construction’ is defined. Potential applications derived from an industrial workshop are presented and results from a series of preliminary studies indicate the viability of mega-scale Rapid Manufacturing for construction.