Prefabricated Construction using Digitally Integrated Industrial Manufacturing

Abstract

The paper describes research being carried out in relation to prefabricated high density affordable housing under a grant from the Partnership for the Advancement of Technology in Housing (PATH) and the National Science Foundation (NSF) in the USA. The objective is to demonstrate how a new paradigm for the conceptualization and construction of buildings can be conceived of as an entirely factory based process that creates advantages for construction through industrial systems technology transfer. Our approach is intended to transform design methodology through demonstrating how alternative construction concepts, using entirely pre-manufactured volumetric units, can be adopted. This involves digital modeling that facilitates parametric variations for creating customized prefabricated products from design conceptualization through to final product delivery. The paper discusses key areas under investigation in relation to a manufacturing paradigm used in the automotive industry that integrates virtual prototyping and industrial manufacturing systems. Our research explores a type of monocoque volumetric unit prefabricated in steel, which will be pre-finished as part of a modular factory-built approach using industrialized methodologies that will facilitate customized manufacture of a high quality energy efficient product for affordable housing. The paper addresses the automotive industry methods of manufacture that have served increased automobile performance and economics through mass production for over a century. In stark contrast, the building industry and in particular the housing industry is still a century behind. It is suggested that a move away from tradition will require an industry wide initiative, just like Henry Ford led the way with mass production. By embracing the increasing sophistication and capability that digital technology offers, it is shown how digital tools are implemented towards mass customization in house design using virtual modeling in the context of a prefabricated manufacturing approach. This includes industrialized modular sub-assembly design, where the information on parts, assemblies and modules can be transferred to digital and robotic technology, as seen in the automotive industry, as well as achieving enhanced production efficiency through a ‘supply chain' process, which is condensed. The paper discusses how these models for manufacture can be transferred into the housing market in order to revolutionize the cost and quality base of construction. Our research objective is to disseminate knowledge on this process, and showing how through integrated transfer of automotive technologies we can implement an industrialized fabrication process for mass housing, not previously known in the building industry. A key focus of our evolving research and development is to enable mass customization or delayed differentiation through virtual prototyping that becomes the central organizing element for design. This transfers through to the supply and implementation of housing using industrialized production line manufacture of a product. The expected outcomes of this research and the conclusions drawn in this paper will demonstrate the means by which to achieve more accessibility to affordable housing for society at large and how through successful design integration and an industrial basis for manufacture will provide an adaptable set of affordable housing typologies for diverse demographic needs.