Introduction

HP SitePrint is a new robotic layout solution for building construction. Instead of using the traditional manual layout. marking chalk by hand, it uses robotics and automation to mark the future locations of walls, conduits, wires and other architectural features accurately and efficiently. With assistance from HP's MJF technology, the device went from concept to launch in less than two years.

HP's MJF technology provided HP's Construction Services team with a speed-to-market advantage that enabled them to develop their product in partnership with customers, and quickly incorporate their feedback. Simultaneously they were able to validate the business model, develop a sales and service channel, and identify and resolve compliance and regulatory issues. As a result they saved months off the product's development timeline and are presently solving a costly problem for the construction industry.

Background

'There is a step in construction called layout, which is essentially marking on the slab where architectural and other features will be placed," says HP Construction Services Director, Xavi Juarez. "Most of the information about a building's design is digital and much of it is already in the cloud, yet on the job site many companies are still marking the floor with tape measures and chalk."

Architectural plans play a pivotal role in large-scale construction projects. From concept to completion, they guide the process by communicating the overall concept and vision while also providing detail and documentation on all aspects, including structural integration and the layout and coordination of mechanical, electrical and plumbing services.

During construction, lines are typically drawn on the slab to indicate the location of walls, windows, stairs, and other architectural elements. Lines are also used to mark the placement of cables, conduit, ductwork and pipe required by the plan.

In the initial phases, surveyors and civil engineers use stakes, flags and spray paint to mark boundaries, foundation lines, and utilities. During the construction phase, iron workers use chalk lines to mark the location of steel beams, columns and other structural elements. Carpenters and drywallers use chalk lines and laser levels to mark walls, partitions, and for floor leveling references. Subcontractors like plumbers, electricians and HVAC installers use lines to mark their respective installations. In the finishing stages, painters and other contractors use lines to mark the boundaries of different paint colors, to indicate choice of flooring material and for other purposes.

Problem

"A client recently told us that they spend billions of dollars to design architectural plans and manage them on the cloud," says Mr. Juarez. 'They can literally account for every wall and screw. But at the end of the line they still have someone with a rope and chalk, marking it all on the ground. It's labor intensive and amplifies the potential for errors."

Drawing lines is time consuming and labor intensive

To properly mark each line, project managers must:

• Review the architectural plans and identify the scale, dimensions, and locations of each feature.
• Clean and prepare the floor surface.
• Using chalk, tape or a laser, mark reference points which will serve as guides to draw the final lines.
• Following the scale and dimensions of the drawings, use a tape measure, ruler, protractor, and other analog tools, or a digital device to measure and mark the distances and angles of each element.
• Use the appropriate line style and weight.
• Check the accuracy and alignment of the lines by comparing them to the architectural drawings and reference points.
• Remove or edit any unnecessary or incorrect lines.
• Clean and prepare the slab surface for the next stage of construction.

Drawing lines by hand is also error prone

Overall, rework, poor communication and bad data management can cost the average midsize construction company more than $2 billion annually. While industry research suggests the direct cost of errors averages 5% of the contract value, indirect costs like productivity loss, safety hazards, and legal and contractual disputes can drive the cost much higher, from 10% to as much as 25% of a job's price.

If personnel aren't qualified, the designs and plans aren't clear, or there are gaps in quality and inspection processes, an incorrectly drawn line can become a significant expense. The costs are difficult to generalize and can vary significantly depending on several factors:

• Stage of construction- An error caught early enough might only require lines to be redrawn, but as the project progresses, an error becomes more impactful. For example an error found after framing or other work is completed can result in demolition and rework, significantly amplifying cost.
• Project size and complexity- Large projects require more capital, materials, and labor, making the cost of errors proportionately larger.
• Fluctuating material and labor cost- The cost of labor and materials to fix the error may be significantly more costly than originally planned.

Drawbacks of physical marking methods

Physical methods for marking floors each have their limitations.

Chalk

While chalk is inexpensive and relatively easy to use, it can also easily be erased or smudged by foot traffic, weather and other factors. Chalk lines can also be inaccurate if the string is not pulled properly or the surface is uneven. Chalk lines can be hard to see on dark and dusty surfaces, and in bright or low light conditions.

Chalk lines can even damage some surfaces. As a result laborers must pay special attention when selecting a chalk type and color, and must consider if and when it must be protected or reapplied.

Tape

While tape can be more durable than chalk, it also has several limitations. Tape lines require significant time and skilled labor as they can be difficult to apply and remove, especially on rough or uneven surfaces. Tape lines also require frequent maintenance, as they are prone to peeling and tearing, especially outdoors and in high traffic areas. Generic tape is limited in material, color, width and style, and specialized tape can be costly.

Other technologies

Laser

Lasers have become increasingly prevalent in the construction industry because of their accuracy and efficiency, but lasers are also limited and have their own drawbacks, including safety. If not handled properly, lasers can cause eye damage and skin burns. As a result. users need to follow safety guidelines and must sometimes wear protective gear. Lasers can be expensive to purchase and maintain, often requiring users to calibrate and make adjustments to ensure they remain in suitable working condition. Lasers are also impacted by environmental factors such as vibration, dust. humidity and temperature, which can reduce their accuracy and visibility.

Virtual reality

Virtual Reality (VR) and Augmented Reality (AR) solutions are gaining acceptance in the architecture, engineering and construction industries to enhance visualization, improve communication, and optimize project efficiency. Virtual floor marking laser projectors, for example, are being employed to display lines on construction floors and other surfaces. While they can be an efficient solution, they are expensive to purchase, require proper calibration and precise alignment. and are prone to interference from dust debris, light and other sources.

Hardware is hard

While other emerging technologies like Artificial Intelligence, Robotics, and Autonomy are available and could vastly improve the construction layout process, they can be difficult to implement without the right hardware. Traditional manufacturing methods are great for mass production but are of little help when developing a new solution. In the early stages you must be able to produce parts in small batches and be highly responsive to customer feedback. Resulting modifications must be easy to implement and field upgradable.

Solution

"HP has participated in the process for years," says Mr. Juarez. "We printed the CAD drawings. Our customers went from printing on paper with us to marking the slab with chalk. The last step was all manual. With HP's 3D printing technology and our experience with hardware, robotics and automation we were positioned to solve a lingering and expensive problem."

HP SitePrint was developed to address the challenges associated with current construction floor marking methods. Its purpose is to provide clear and detailed guidance for contractors and their workers.

Leveraging HP's considerable experience in robotics and printing, HP SitePrint is an autonomous robot that prints lines, arcs, points, text and other elements, directly on the slab of a construction site.

HP SitePrint is designed to work on different types of surfaces in a variety of weather conditions and construction environments. Thanks to an array of sensors and a unique tracking system, HP SitePrint can navigate the site autonomously, avoiding obstacles and cliffs. It can print on an assortment of materials ranging from vinyl and plywood to tarmac and concrete using water or solvent-based inks.

To set up and operate the HP SitePrint solution, users submit a computer-aided design (CAD) file to the HP SitePrint Cloud. The Cloud allows users to create projects and manage drawings, keep track of the layout progress, and manage costs, ensuring there is communication among stakeholders. Once the HP SitePrint arrives at the jobsite, using an HP SitePrint User Interface (UI), operators can view their CAD documents, submit the job they want to print adjust settings, set up the Robotic Total Station, and track the robot's navigation. Working in tandem, HP's compatibility with Total Robotic Stations measures angles and distances and communicates wirelessly with the robot aligning the robot with control points and guiding it during the printing process.

What types of sites are ideal for HP SitePrint?

"It can take a team of two or three highly skilled people two weeks to mark up a slab during construction of a hospital," says Mr. Juarez. "With HP SitePrint they can accomplish the same task up to ten times faster, accurately completing the work in just a few days."

Hospitals

Health care facilities have several unique construction features that cater to their specific needs and requirements. They prioritize cleanliness and minimize the spread of pathogens with anti-microbial surfaces, negative pressure rooms, and HEPA filtration systems. Hospitals are also designed to be modular and efficient with strategic placement of departments and multiple transport routes for staff and patients. Further, many hospitals are incorporating sustainability into new construction projects by tapping into alternative energy, utilizing high efficiency lighting and heating, conserving water and using recycled materials.

HP SitePrint enables project managers to mark lines quickly and accurately on hospital floors. The additional points and text it prints can help construction teams and subcontractors locate and install each unique service, while also making them aware of hazards, clean areas and other aspects unique to healthcare facilities.

Schools

With school construction projects, there are several unique challenges when marking floors. Schools are designed with technology in mind. Projectors, screens, sound systems, wired and wireless networking, and security systems are all prevalent and are no longer confined to the classroom. They also extend to offices, hallways, common areas, cafeterias and sports facilities. In addition, schools are focused on safety and security. They now emphasize windows and clear lines of sight even between floors, to help reduce vulnerability and enhance the learning environment.

HP SitePrint assimilates the abundance of cabling and fixtures used in school construction and precisely marks their location. HP SitePrint can also accurately mark unique architectural features while avoiding obstacles, thanks to its X3 LiDAR sensors, and cliffs with its X4 Safety sensors, which not only prevent accidental falls, but also help it comply with security regulations.

Data Centers

When building a data center, floor marking plays a crucial role in ensuring efficiency, safety and effective utilization of space. Data centers utilize scalable, flexible space, and have unique energy and environmental requirements. They require special climate control and ventilation and are built with redundant systems for power, cooling and networking. In addition they are highly secure, with access control and security systems, and have sophisticated fire suppression and safety measures. The electrical infrastructure and network architecture in a data center are highly complex. Even lighting and signage needs are unique.

"Once marking information on the slab becomes easy you start thinking about how you can add text and other points," says Mr. Juarez. 'They might be redundant but if additional markings help reduce errors down the line, they are easily worthwhile."

HP SitePrint enables project managers to upload CAD blueprints for the unique features of a data center and allows collaboration between contractors to ensure all lines are visible and accurately depicted. Once approved the HP SitePrint robot marks them on the slab, minimizing errors and ensuring all services are visible to teams working on the job.

HP 3D Printing makes it possible

HP SitePrint began as an idea within the Large Format Business, which then transformed to the Construction Services Organization. The concept was incubated by a small team of engineers who believed a compact versatile robot that is robust enough to adapt to construction sites could resolve a major challenge for the construction industry by marking slabs more quickly and accurately than the traditional manual layout. They had considerable experience in printing and automation, and worked with consultants and experts on aspects related to robotics.

"We knew we had identified a market gap where there was no competition, but the window on those opportunities closes rapidly," says Mr. Juarez. "The key to getting this product to market quickly was to be fast in every iteration. HP 3D printing made it possible."

In late 2021, the Construction Services team developed their first prototype. Using HP's Multi Jet Fusion (MJF) 3D printing, they quickly developed the parts needed to make a functional machine. In 2022, they conducted market research, modified their design and scaled up for production. Beginning in early 2023, they produced approximately 50 industrialized prototypes, over half of which were used in the field for early customer trials.

"Early on. we wanted to involve end customers to help validate the solution," says HP SitePrint Program Manager, Eduardo Martin. 'This is a new market and we wanted to collect as much feedback as possible, and in parallel. implement it into the product."

With the customer feedback they received. the team made several iterations to the robot. helping it manage the real-world conditions and abuse it experienced on construction sites. Having a field-ready product also helped them determine the business model, build a sales and service channel and a funnel of prospective customers.

"We are not just selling machines, we are offering 'robotics as-a-service," says Mr. Martin. "Customers don't pay for the device. they pay per square meter of print. To validate the business model, we had to ensure that compliance and regulatory requirements were met and also confirm our billing and reporting models were accurate."

HP MJF is a production technology

Typically as demand grows for a product companies may consider moving from 3D printing to a more traditional manufacturing technology. But in this example, HP found that it could scale without changing its manufacturing process.

In July 2023, HP launched SitePrint. The current iteration of the robot has 275 parts. including 38 individual parts that were produced with HP's MJF additive manufacturing solution. They make up 51% of the machine's plastic parts. yet account for only 6% of the total machine cost.

Benefits

HP SitePrint is a breakthrough solution that leverages printing and robotics to transform the way floors are marked in large-scale construction projects. The solution offers many important benefits for the industry, including:

• Accurate layout-HP's technology utilizes CAD data and robotics to create precise layouts and digitally prints building blueprints directly on the slab, ensuring accuracy and eliminating human error.
• Terrain diversity-HP SitePrint offers a range of inks and works on a variety of rough and bumpy surfaces, making it suitable for many construction environments.
• Increased productivity-HP SitePrint can mark floors up to 10 times faster1 than conventional methods.
• Cost savings-Reducing the labor associated with manual layout cost, allowing construction teams to focus on other high-value tasks.
• Ease of use-HP SitePrint is a comprehensive construction layout management system that enables users to move between sites, set up the device, and initiate the printing process easily and seamlessly.
• Powerful information-In addition to lines, the HP SitePrint robot prints points, arcs, and text, providing new information that improves on-site communication, minimizing the cost of errors and redos.
• Cloud management-HP SitePrint Cloud allows users to share and collaborate on CAD files, in addition to monitoring job progress and generating reports. Like other cloud applications, it is also scalable, accessible, and secure, making it ideal for large and sensitive projects.

3D Printing's ongoing value

"HP MJF technology easily saved six months to a year off of our development timeline," says Mr. Martin. "We were able to get industrial prototypes into the field far earlier than we would have using traditional manufacturing methods. In tandem, 3D printing enabled us to develop a sales and service channel and resolve the compliance and regulatory issues associated with this type of product."

HP's MJF 3D printing solution was invaluable to the Construction Services team and offered many important advantages:

• Speed-to-market-In the early stages, engineers were able to create functional prototypes in less time than they could with other methods. As customer feedback arrived, they were able to modify and improve each iteration. Prior to launch, they didn't need to plan for a new process, as they planned to use 3D printing throughout the product's lifecycle. This speed advantage allowed them to take a complex hardware product from concept to completion in less than two years.
• Design freedom-with HP MJF the team wasn't limited to traditional design techniques. They could use 3D printing to develop complex parts that could be produced any other way, and combine parts to reduce cost and simplify assembly.
• Economics-3D printing is a digital process where parts are built directly from CAD files. Other processes require tooling and significant machine make-ready. By eliminating these expensive up-front costs, HP's MJF can produce short-runs less expensively, and unlock opportunities with just-in-time and "on demand" manufacturing.
• Customization-As customer needs continue to be uncovered, the team can easily modify and augment HP SitePrint to meet new demands. Those innovations can be customer-specific or incorporated into the product's main feature set.

It can be hard to communicate the advantages of design freedom," says Mr. Martin. "When we were developing the robot's printing capabilities, we wanted to utilize the cartridges from our DesignJet 2D printers. The robot is a much smaller device, and we faced many constraints on where and how to fit them. Since we didn't have to deal with the limitations of a mold, or machining, we could create part geometries that are extremely complex. That allowed us to fit the cartridge inside."

Future Development

HP Construction Services is also considering how its other technologies can help augment and improve HP SitePrint. For example, the 2D Large Format Printing team has proposed using Latex Technology to customize the robot's outer shell to feature and highlight the branding of resellers and end customers. The team is also considering how HP's Metal Jet 3D Printing technology can be employed. They have identified specific metal parts that could benefit from increased design freedom and faster speed to market. Once those parts are produced, tested, and validated, HP's Construction Services team expects to implement them.

The team is also considering how HP's Metal Jet 3D Printing technology can be employed. They have identified specific metal parts that could benefit from increased design freedom and faster speed to market. Once those parts are produced, tested and validated, HP's Construction Services team expects they will be implemented into the final product.

"One thing I can say for certain is that HP 3D printing saved us considerable time and allowed us to economically produce small volumes of parts," says Mr. Martin. "I would suggest that other product developers consider how they can use MJF to improve their products and go to market more quickly. Start small, with just a few parts, but realize the technology is addictive and soon you will be using it more and more."

Learn more about HP SitePrint by visiting https://www.hp.com/us-en/printers/site-print/layout-robot.html

The content & opinions in this article are the author’s and do not necessarily represent the views of RoboticsTomorrow

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