Drone built structure new construction workers

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Drone-built structure: The new construction workers

The versatility of flying drones makes them attractive builders, able to take on tasks that would be too risky for human workers.

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Quantumrun Foresight
June 21, 2023

Insight highlights

The potential of 3D printing in the construction industry is expanding with the introduction of autonomous flying drones that can build structures on the wing, paving the way for faster construction with less waste. In 2022, researchers from Imperial College London and Empa developed flying 3D-printing robots, akin to bees and wasps, capable of building structures in difficult areas, such as disaster zones or tall buildings. Initial tests have been promising, and while further improvements in large-scale construction and materials science are necessary, certain patterns and geometric designs are deemed ideal for drone construction.

Drone-built structure context

Three-dimensional printing (sometimes called additive manufacturing) is a manufacturing process that has been heavily researched and optimized for different objects. However, since 2017, robotic arm prototypes built for trial projects in North America and Asia have been 3D-printing houses and bridges. And in 2020, researchers discovered how to 3D-print whole buildings using Additive Manufacturing Building Processes (AMBP). While the initial results tended to be simplistic, restricting building designs, the proof of concept demonstrated a potential future where homes and structures can be built faster and with less waste.

Several universities have furthermore explored building swarms of autonomous flying drones for constructing 3D printed buildings. An example is the UK-based University of Bath, which released a paper in 2017 that discussed design considerations when using 3D-printing drones. One concern was that a 3D-printed building shell needs to be sturdy enough to support its weight and withstand occasional wind gusts.

How materials are loaded onto the drone is another essential consideration. The materials must be transported by drone to the site, placed accurately, and acquire enough strength quickly so that it stays in place so that more materials can be deposited on top. Liquids that solidify quickly, like cement-based materials, were mentioned as the best solution for this purpose.

3D-printed drone construction ought to be able to self-correct during printing. This feature is paramount because there are many sources of potential defects and inaccuracies when using this method. For example, the drone's geolocation might be off, or the materials may be affected by wind and temperature.

Disruptive impact

In 2022, flying 3D-printing robots, similar to bees and wasps, were developed by researchers from Imperial College London and Empa and Switzerland-based Federal Laboratories of Materials Science and Technology. As they fly, these drones can build structures on the wing, making them perfect for work in difficult spots like disaster zones or tall buildings. The drones work together to deposit layers of material following a digital design, adapting their movements as they build.

While these machines are fully autonomous, a human controller still monitors them. "BuildDrones" make up the fleet and deposit materials while flying. "ScanDrones" also help monitor the output and keep everything running smoothly. The drones are constantly measuring the progress and will automatically adjust themselves, all while staying within five millimeters of where they're constructing.

Initial tests had these drones build a 2-meter high cylinder comprising 72 layers of polyurethane-based foam and an 18-centimeter cylinder incorporating 28 layers of a cement-like material. Researchers believe that while initial studies are promising, there need to be more experiments with large-scale construction and improvements in materials science. Nonetheless, the team thinks specific patterns and geometric designs are well-suited for drone construction.

Implications of drone-built structure

Wider implications of drone-built structures may include:

Drones being used to build more risky structures, like nuclear plants, offshore wind turbines, and electricity grids.

More investments in developing lighter, flexible, and sustainable construction materials, like mycelium, that are easier for drones to transport and build around.

Large-scale construction companies (likely partnering with startups) to develop the infrastructure needed (e.g., sensors, cameras, Internet of Things devices) for highly mobile construction robots to operate effectively.