Raphael ThysResearchers at Oak Ridge National Laboratory and the University of Maine have developed a 3D printed, recyclable floor panel from natural materials. These floor panels are strong enough to replace steel in construction. This project is part of the Sustainable Materials & Manufacturing Alliance for Renewable Technologies (SM2ART) program.
Displayed at the 2024 Housing Innovation Showcase, the SM2ART Nfloor cassette panel aims to replace traditional steel-and-concrete assemblies, potentially making multistory buildings more eco-friendly. This advancement is significant for modular construction, which involves assembling building sections offsite before final assembly at the construction site.
An ORNL researcher ORNL assessing a construction process on a mock-up building site.. (Image Credit: ORNL)
The panel is made from polylactic acid (PLA) and wood flour, both biodegradable materials. PLA is derived from corn residue, while wood flour is a byproduct of lumber processing. This blend results in a strong, recyclable material suitable for large-format 3D printing.
“By utilizing bio-based, large-scale 3D printing, we replaced an assembly made from 31 parts and three materials with a single-material floor panel that is ecologically friendly, and with the same strength as traditional steel floor fabrication,” said Katie Copperhaver, researcher at IRNL.
Using a large-scale 3D printer, researchers created the SM2ART Nfloor cassette in approximately 30 hours, reducing labor by about 33% compared to traditional steel floor fabrication. Scott Tomlinson from the University of Maine noted that the single-piece assembly is stiffer and provides a better walking experience than conventional steel-concrete floors.
This development underscores the potential of using organic materials in modular, multi residential buildings, enhancing sustainability in urban construction.
Source: ornl.gov