[Andrey Rudenko] is building a house in his garage. Not with nails and lumber, but with concrete extruded by his 3D printer. We’ve seen concrete 3D printers in the past, but unlike those projects, [Andrey] isn’t part of a of a university or corporation. He’s just a contractor with a dream. His printer is directly derived from the RepRap project. It’s even commanded by Pronterface.
[Andrey] started with an Arduino Mega 2560 based RepRap RAMPS style controller. His big printer needed big NEMA34 stepper motors, far beyond the current capacity of the stock RAMPS stepper drivers. [Andrey] got in touch with [James] at MassMind who helped him with an open source THB6064AH based driver. [James] even came up with an adaptor cable and PCB which makes the new drivers a drop-in replacement.
Now that his printer was moving, [Andrey] needed a material to print. Concrete chemistry is a science all its own. There are many specialty blends of concrete with specific strength and drying times. Trucking in custom mixtures can get expensive. [Andrey] has come up with his own mixture based on bags of regular concrete mix, sand, and some additives. [Andrey's] special sauce doesn’t cure especially quickly, but it is viscous enough to print with.
Every piece of [Andrey's] printer had to be designed and refined, including the nozzle. The concrete printer works somewhat like a frostruder, extruding concrete in 20mm wide by 5mm tall layers. He’s even managed to print overhanging layers and arches exactly like a giant RepRap Mendel.
The printer’s great unveiling will be this summer. [Andrey] plans to print a playhouse sized castle over the course of a week. He’s looking to collaborate with architects, builders, and other like-minded folks. We’d suggest uploading the project to Hackaday.io!
An example of the printer’s output:
[Andrey's] printer today:
One of [Andrey's] early prototypes: