Periodic Reporting for period 1 - Svelte (Efficient manufacturing technology for complex architecture)
Berichtszeitraum: 2021-01-01 bis 2021-12-31
Context
Today, buildings use significant more concrete than structurally needed. This is due to a technological limitation that makes using efficient designs - based mostly on complex shapes, to expensive. Therefore, the common building methods rely on square shapes with planar surfaces, such as regular flat walls and floors. By using this traditional approach ~30% of the total concrete mass of a building is considered waste as it does not have a structural purposes and acts as dead-weight. As the world is going through the largest wave of urbanization in history and key resources in the construction are rapidly depleted, the building sector must evolve towards implementing solutions that improve the material consumption efficiency.
The challenge:
->Buildings often require significantly more material than is structurally necessary.
->Construction sand will be depleted in the next 30 to 40 years.
->Construction sector emits 36% of the world's CO2.
Running a load analysis on construction structures shows that a significant volume of concrete in traditional buildings does not fulfil a structural. This dead-weight can be safely removed and replaced with more sustainable materials by using complex geometry to generate strength.
The limitation is that the resulting surface to be replaced has an irregular and unique shape and today there is no way today in which to efficiently produce these so-called ‘double-curved’ surfaces in large numbers, affordably and speedily.
The Svelte solution and its impact
->A new tool to improve the weight-to-strength ratio of buildings.
->Use no more concrete than structurally needed - up to 30% less.
->Reduce the emissions by using less materials and inherently less transportation.
Svelte developed fully in-house a machine-system working on an innovative technology dedicated to generating double-curved moulds more efficiently than current solutions.
The Svelte solution by-passes CNCs and recreates any double-curved surface, no matter how complex, at constant speed, with a high degree of accuracy (=/- 0.6mm) in a single operation that reduces the production time of a 1x1m surface from 5-10 hours to 8 minutes.
As a result of its high-speed process, the solution holds enormous potential: it can deliver double-curved moulds 60x faster and 50% cheaper for realizing topologically optimized structures, affordable architectural panels, but also for other industries with a high usage of complex shapes such as curved glass, shipbuilding, and the production of blades for onshore/offshore wind turbines.
Most importantly, Svelte aims to becoming a key enabler for topologically optimized, greener construction by using less materials than traditional construction. Walls, floors and supporting beams can be optimized to use less concrete by integrating Svelte produced shapes, adding up to 30% savings in construction materials while providing the same or improved structural properties.
EIC project objectives: ecology through optimization in construction
Within the EIC Accelerator grant project, Svelte sets to complete the optimization of its machine-system and build its first industrial-ready prototype ready to be scaled to commence commercialization under both a FIAB model, but also as a SaaS solution by producing moulds and panels in its own production facility. Within the scope of the project, Svelte’s innovative solution will be tested with real market stakeholders and potential customers across 4 pilots in different fields of application. This will enable us to draw conclusions and act on how to better our production processes to meet real market requirements.
Furthermore, Svelte will invest part of the grant into ensuring its solution is ISO & CE Certified, and its technology is protected through two more patents, so Svelte’s innovative assets are prepared for future exploitation.
Today, buildings use significant more concrete than structurally needed. This is due to a technological limitation that makes using efficient designs - based mostly on complex shapes, to expensive. Therefore, the common building methods rely on square shapes with planar surfaces, such as regular flat walls and floors. By using this traditional approach ~30% of the total concrete mass of a building is considered waste as it does not have a structural purposes and acts as dead-weight. As the world is going through the largest wave of urbanization in history and key resources in the construction are rapidly depleted, the building sector must evolve towards implementing solutions that improve the material consumption efficiency.
The challenge:
->Buildings often require significantly more material than is structurally necessary.
->Construction sand will be depleted in the next 30 to 40 years.
->Construction sector emits 36% of the world's CO2.
Running a load analysis on construction structures shows that a significant volume of concrete in traditional buildings does not fulfil a structural. This dead-weight can be safely removed and replaced with more sustainable materials by using complex geometry to generate strength.
The limitation is that the resulting surface to be replaced has an irregular and unique shape and today there is no way today in which to efficiently produce these so-called ‘double-curved’ surfaces in large numbers, affordably and speedily.
The Svelte solution and its impact
->A new tool to improve the weight-to-strength ratio of buildings.
->Use no more concrete than structurally needed - up to 30% less.
->Reduce the emissions by using less materials and inherently less transportation.
Svelte developed fully in-house a machine-system working on an innovative technology dedicated to generating double-curved moulds more efficiently than current solutions.
The Svelte solution by-passes CNCs and recreates any double-curved surface, no matter how complex, at constant speed, with a high degree of accuracy (=/- 0.6mm) in a single operation that reduces the production time of a 1x1m surface from 5-10 hours to 8 minutes.
As a result of its high-speed process, the solution holds enormous potential: it can deliver double-curved moulds 60x faster and 50% cheaper for realizing topologically optimized structures, affordable architectural panels, but also for other industries with a high usage of complex shapes such as curved glass, shipbuilding, and the production of blades for onshore/offshore wind turbines.
Most importantly, Svelte aims to becoming a key enabler for topologically optimized, greener construction by using less materials than traditional construction. Walls, floors and supporting beams can be optimized to use less concrete by integrating Svelte produced shapes, adding up to 30% savings in construction materials while providing the same or improved structural properties.
EIC project objectives: ecology through optimization in construction
Within the EIC Accelerator grant project, Svelte sets to complete the optimization of its machine-system and build its first industrial-ready prototype ready to be scaled to commence commercialization under both a FIAB model, but also as a SaaS solution by producing moulds and panels in its own production facility. Within the scope of the project, Svelte’s innovative solution will be tested with real market stakeholders and potential customers across 4 pilots in different fields of application. This will enable us to draw conclusions and act on how to better our production processes to meet real market requirements.
Furthermore, Svelte will invest part of the grant into ensuring its solution is ISO & CE Certified, and its technology is protected through two more patents, so Svelte’s innovative assets are prepared for future exploitation.
Within the reporting period timeframe, Svelte redesigned the initial design of its machine-system and has performed multiple iterations to validate, test and optimize the best use of materials, components, and systems to be used in preparation for Svelte’s first market-ready industrial prototype to be completed by the end of the EIC project.
The approach to the technical development was prioritising by the degree of risk posed by each task. We first validated that the software & firmware can be engineered to perform the complexity demanded by our solution. Secondly, we focused on finding and testing an industrial-grade automation system to handle such complexity for which the market currently holds no dedicated solution. Once these risks were mitigated, we moved towards assembling the mechanics of the machine-system.
In parallel with the technical development activities, the Svelte team has been interacting with various stakeholders in the construction sector to better understand their needs and expectation and adapt the Svelte solution for an ideal market fit.
Various tech testing was conducted and pilot projects have commenced, also prioritised by degree of risk due to complexity. We are running an on-site casting of stairs together with a precast construction industrial partner, with the purpose of comparing regular stairs casting methods with Svelte-optimised moulds produced for the same purpose, measuring the advantages in terms of mould reusability, production time and costs cuts, and material reduction.
Furthermore, Svelte featured in the established Zeppelin magazine on architecture, design and urban culture. No lastly, Svelte was present at BIBM 2021 - the largest congress of the European Federation for the Precast Concrete Industry to present its ongoing EIC Accelerator project progress and to attract new potential pilot partners.
The approach to the technical development was prioritising by the degree of risk posed by each task. We first validated that the software & firmware can be engineered to perform the complexity demanded by our solution. Secondly, we focused on finding and testing an industrial-grade automation system to handle such complexity for which the market currently holds no dedicated solution. Once these risks were mitigated, we moved towards assembling the mechanics of the machine-system.
In parallel with the technical development activities, the Svelte team has been interacting with various stakeholders in the construction sector to better understand their needs and expectation and adapt the Svelte solution for an ideal market fit.
Various tech testing was conducted and pilot projects have commenced, also prioritised by degree of risk due to complexity. We are running an on-site casting of stairs together with a precast construction industrial partner, with the purpose of comparing regular stairs casting methods with Svelte-optimised moulds produced for the same purpose, measuring the advantages in terms of mould reusability, production time and costs cuts, and material reduction.
Furthermore, Svelte featured in the established Zeppelin magazine on architecture, design and urban culture. No lastly, Svelte was present at BIBM 2021 - the largest congress of the European Federation for the Precast Concrete Industry to present its ongoing EIC Accelerator project progress and to attract new potential pilot partners.
Traditional construction - which largely makes use of flat surfaces in building designs - requires significantly more material than it is structurally needed. On the background of the climate crisis & resource depletion, the construction industry – world’s most polluting industry, responsible for an incredible 36% of total GHG emissions, has the opportunity to build a new economic model. A reliable future in constructions is fundamentally bound to using materials more efficiently & sustainably. Svelte’s 30% savings in materials per construction project further adds up to significant savings in energy, water, sand, CO2, methane, NOX and PM10 particles. To put things into perspective, just 650 Svelte Systems could reduce emissions from constructions by 1% in Europe. Furthermore, during the project’s R&D activities, Svelte identified a new sustainability opportunity by integrating an EPS compactor which upcycles the excess foam material generated while producing the Svelte moulds.