MudBots 3D Concrete Printers

Consumers are tired of the costs associated with conceptual designs. Traditional construction is limiting without astronomical costs. Architects have the ideas, but most consumers aren’t willing to pay for them. With a printer the cost between boring and amazing is the same.

We’ve been told that if the printer wasn’t any faster and wasn’t any cheaper to build with, it would still be the most significant tool ever, because it allows architects everywhere to begin offering designs that were cost prohibitive in the past.

The key to printing without stopping every 12″ as seen by the rest of the world, is utilizing a batch plant that meters all the dry and liquid ingredients as the temperature, wind and humidity change. the mix formula being used at 5am is not the mix being used an hour later. MudBots provides a variety of mix formulas with differing strengths and cure times without being forced to buy proprietary mixes and paying 5 times as much when everything needed is already available at local batch plants.

The mix is batched on site after which, the liquid ingredients are added to the dry mixes and mixed for delivery to a computer-controlled pump, which works in unison with the printer to control nozzle speed, and the volume rate of material at the nozzle.

Once the 3D model is ready, the STL file is imported into a slicing software, where the height of each printed pass is specified. After slicing the model into individual print passes, the system exports the code which is interpreted into actual nozzle movement.

The next step is to conceptualize a 2D design using a CAD program, and then converting the design to a 3D model using any 3D software that can export an STL file.

There are hundreds of different mix formulas that closely resemble a mortar type mix. Each mix requires months of testing for different characteristics, such as fluidity, bonding, water impenetrability, Seismic resistance, as well as curing and strength. Mixes are designed for 1200 PSI up to 10,000 PSI, depending on the structure and engineered objectives.

Concrete Printing (3DCP) is possible with the construction of a large 3D printer capable of printing large scale structures, from spas and barbeques to homes and larger commercial buildings, without the need of traditional framing, forming or blocks. MudBots offers printers from 15′ x 15′ up to 100′ x 100′.

Use this worksheet to determine the Cubic Inch Cost of the ingredients that will be used in the specialty mix for printing.

Complete the worksheet to have a better idea of where you will save in terms of Materials and Labor.

Very seldom do we see breathtaking signage. Everyone is looking for ways to stand out, but it keeps getting back to budgets. Imagine the development entries that are possible now. These printers like to print and with everything they can do, it would be foolish to have any down time.

By now, you may be realizing how significantly concrete printing is about to change so many industries. Pool and spa is just another market that will benefit. The cost for traditional pool construction is about to change. Homes can be sold with included water features at a fractional cost.

The 3D Concrete Printer is a landscaper’s dream. Never before could you have offered products at a fraction the cost of your competition while still earning profits. It is basically unheard of. Developers will rethink their offerings when they realize how affordable the little extras are. The extras will set them apart from all the others.

More and more customers are starting to experiment with additional uses. Underground is definitely something worth considering. The cost is high for underground but can be significantly reduced by printing on site.

Additionally, house plans can be modified to allow for dome roofing, which can also eliminate trussing and sheeting costs. The truss system utilizes the same printer, but with the use of a different mixer/pumping system. As new advances become available, they will be bolt-on solutions with your existing printer.

You can have any R Factor you want depending on the density and material. A solid concrete wall has an R9 Value. If you print a hollow wall and back fill with fiberglass, polystyrene or cellulose, you can achieve any R value you desire.

No paper, mesh or additive material is needed. This isn’t a process that is done days after framing and sheeting. The finish is done real time as the wall is printing.

If builders want to finish the smooth walls with a knock down broquet, orange peel or other finish, just come back the next day and spray with a hopper, top coat and trowel.

Some print finishes may not need to be finished if acceptable to the customer. Taping takes days for each coat to dry. This is not the case with mason finishing. Within 3 hours of the walls being printed, the walls are already finished.

You will still need to hang the lid, but not the walls. This goes for the basement. Just trowel the printed wall and when done, it’s as smooth as a 3-coat drywall. Most countries do not wood frame at all. They build with bricks and then send a crew of mason finishers, and when it’s done, it’s smooth as anything.

This isn’t necessary as walls can be printed hollow. Same as above. Your electrical and plumbing will be less expensive.

This is not necessary as walls can be printed that are hollow. Depending on the mix that is used, there is also no need for rebar or solid pour exterior and bearing walls. We know the idea of exterior walls and bearing walls without rebar seems ridiculous, but it’s time to learn something new. Look up 20,000 PSI concrete and geopolymer. It’s real.

No warped studs, better fire rating, no mildew. No matter how you look at it, printing a home is far better than framing a home. Concrete printing is faster, more accurate, just better all around.

The printer knows where your wall is going to be. No chalk lines needed. Once the slab is poured, all you have to do is hit print.

Our printers easily print basement walls without the need of forming, backfilling, stripping forms, forming interior walls, drywall, insulation or taping. All of this is done by the printer.

Not there yet, but our concrete printer will be finishing slabs within the next 6 to 12 months, and can be ordered as an option. If you’re waiting for all the options to be available before buying, you’ll never buy a printer, because we will never stop innovating. All upgrades will be available and are designed to be added to all of our printers.

The slab layout and forming is critical to all other subs on the job. If a mistake is made at this point of the project, nothing else is square, and all other subs suffer. With the Concrete Printers , the house is square every time.

Perfect level and square forms are printed right from the computer. Grading is also easier, as the only real important level is the 4 corners of the printer. Printer can be set up for uneven grades.

The layout and forming for footings and stem walls are very time-consuming. It takes a lot of lumber, diesel, stakes, and labor that is no longer necessary. Simply level the area, compact them, level the four corners of your printer, and PRINT.

The first cost savings will be the elimination of 3 men, string lines, and marking paint. Simply add the airless attachment to the nozzle of the printer, and your entire layout for footing is done in minutes. Push the printer out of the way and start digging.

Will It Pass Code?

First time callers don’t have any problem recognizing that concrete printing would be far faster and cheaper. They also don’t question the feasibility of learning the tech. The single most asked question relates to passing code. No fear of the tech, just fear of their building department.

Truth is concrete printers are already building homes and commercial buildings all around the world, so when considering the application in your backyard, here are a few things to consider.

ICF Construction

The best way to wrap your head around concrete printing is to start with the basics, and there is no better way than to liken 3D Concrete Printing, or 3DCP, to Insulated Concrete Block construction. ICF code is accepted everywhere yet a foam block has virtually no structural strength at all. So when you are considering how you would pass code, keep ICF in mind. For the most part, a concrete printer is doing nothing more than printing a hollow wall shell that can be filled with rebar and concrete. The only difference is foam has no strength at all, compared to what we print in most cases, which is twice the strength of cinderblock.

CMU Construction

Now with that in mind, let’s look at the similarities with CMU (Cinderblock). No one questions the ability to build with cinderblock. While we don’t encourage it, take into consideration the fact that you can print walls that are the exact dimension and design as cinderblock yet twice as much the strength, and without grouted joints that are susceptible to seismic cracking.

The advantage of concrete printing is the ability to print hollow walls which reduced costs for electrical, plumbing and insulation. Additionally, hollow walls can be insulated to almost an R factor with ease with the absence obstructive studs.

The challenge isn’t whether or not it’s possible, as it’s already being done everywhere. The challenge is whether or not you can find a structural engineer that makes it possible. It’s all about math. The code already exists, all you have to do is exceed the code, and to do that, you need to start with the mix.

Testing and Math

We have developed and tested a myriad of different mixes with different characteristics, such as PSI, tensile strength, water impenetrability, fire resistance, as well as cold weather mixes, hot weather mixes, accelerated mixes, and retarded mixes. We provide the formulas and the lab results that your engineer will need to determine what the wall designs will be. Once they have the testing results, they can design a wall that exceeds any code anywhere.

Some choose to stay close to traditional methods by printing walls that resemble ICF and CMU, but others, who have more confidence, take it all the way by utilizing stronger mixes, so that they can capitalize on ALL the cost-saving benefits.

Plans and Details

As for the other considerations, we have plenty of videos that address common questions about headers, attaching hurricane straps, installing electrical boxes, securing plumbing, mounting top plates for trussing and methods for tying the wall to the foundation. Although, most engineers want to see the methods being used by others first before reinventing the wheel, as they learn more and more until there isn’t a question that they can’t offer up to 4 or 5 solutions when asked. Most of this is common sense, nevertheless, we have the plan details and math to share.

As we’re saying this, bear in mind that every state, and sometimes even cities, have different building codes. What we will share is determined by specific code and conditions that are not specific to your state. Far too many factors come into play, such as mix characteristics, code, water table, frost level, annual snow loads, wind, seismic, soil compaction for starters. We do not provide structural engineering, but we can point you in the right direction.