Researchers 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.
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