Helps Portfolio — StoneForge 3D Printer

StoneForge 3D Printer

The StoneForge is a custom-built concrete 3D printer developed as my master’s thesis and ongoing research project. Designed and engineered over two years as a one-man effort, it features a Duet 6XD control system with multiple independent gantries for precise deposition of cementitious mixtures and reinforcement materials. With robust mechanics, scalable architecture, and advanced toolhead integration, StoneForge serves as both a proof of concept and a research platform for pushing the~ limits of additive manufacturing in construction.

Product informations:

Dimensions: 3.0 x 2.4 x 2.2 m
Build Volume: 1.6 x 1.2 x 1.2 m
Number of gantries: 2 (Current prototype with only 1)
Modular on Y axis
Modular electronics: Duet3 6XD paired with 10 Duet3 1XD boards via CAN BUS-FD
Deposition Gantry Toolhead wheight: up to 50Kg
Reinforcement Gantry Toolhead wheight: up to 15Kg

StoneForge Control Box

As part of the StoneForge 3D Printer development, I designed a custom control box positioned above the main electrical cabinet. This enclosure houses essential operational controls, including a disconnect switch, power switch, emergency stop, and energy meter.

The 3D printed enclosure comprises several components: a two-part main body, a front cover, a top cover, and two rear cable management covers. To achieve a certain degree of waterproofing at all interfaces, custom 3D-printed TPU O-rings were implemented.

The top cover was specifically designed to incorporate a Raspberry Pi 400 and a compact mouse pad, providing an integrated computing solution. Additionally, an 11” display is mounted on an adjustable arm fixed to the rear section of the main body, ensuring ergonomic positioning and user comfort. The front cover provides easy access to essential controls such as the disconnect switch, power button, emergency stop, and energy meter.

Design for Additive Manufacturing (DfAM) principles were applied throughout the development process, minimizing the need for support structures during printing and leveraging the unique capabilities of additive manufacturing technology.