Fast Complexity: Additive Manufacturing for Prefabricated Concrete Slabs

Anton, Ana; Jipa, Andrei; Reiter, Lex; Dillenburger, Benjamin

doi:10.1007/978-3-030-49916-7_102

Cited by 15 publications

(15 citation statements)

References 12 publications

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“…Finally, in 2020, Fast Complexity, a system combining reusable binder-jet 3DPF and DDFC, was proposed for prefabricated discrete post-tensioned slab elements. 79…”

Section: Foam Jettingmentioning

confidence: 99%

“…52 Post-tensioning tendons can also benefit from the precision of 3D printing, and therefore several projects have already proposed the use of 3DPF for prestressed concrete. 59,79,83 Usually, post-tensioning will not eliminate the need for rigid reinforcement entirely. Reinforcement strategies are therefore often combined because they complement each other: posttensioning provides the primary bending reinforcement and rigid bar stirrups can provide shear reinforcement, while fibers or meshes provide secondary crack control reinforcement.…”

Section: Reinforcementmentioning

confidence: 99%

“…Reinforcement strategies are therefore often combined because they complement each other: posttensioning provides the primary bending reinforcement and rigid bar stirrups can provide shear reinforcement, while fibers or meshes provide secondary crack control reinforcement. 79,85 Finally, due to the geometric flexibility of 3D printing, complex shells and slabs can be designed and fabricated to work in compression only. 86 No tension forces occur within the concrete in such structures, and therefore no principal reinforcement is required.…”

Section: Reinforcementmentioning

confidence: 99%

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3D Printed Formwork for Concrete: State-of-the-Art, Opportunities, Challenges, and Applications

Jipa

Dillenburger

2022

3D Printing and Additive Manufacturing

Self Cite

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Concrete is the most used human-made material in the world, and it is responsible for around 8% of the total greenhouse gas emissions worldwide. Hence, efficient concrete construction methods are one of the main foci of research in architecture, civil engineering, and material science. One recent development that promises to achieve this goal is the use of digital fabrication for building components. Most investigations focus on direct extrusion 3D printing with concrete, which has already been covered in several review articles. Conversely, this article reviews a different approach, which focuses on the indirect digital fabrication of concrete through 3D printed formworks. This approach is under investigation for structural and nonstructural, as well as for onand off-site applications, with a number of projects having already been built, but a comprehensive review of 3D printed formworks has not yet been compiled to synthesize the findings. This article provides a comprehensive map of the state-of-the-art of five different 3D printing technologies used for the fabrication of formworks so far. The aim is to serve as a fundamental reference for future research, provide a basis for consistent language in this field, and support the development of construction standards. The article further discusses the new geometric possibilities with 3D printed formworks and their potential for making concrete construction more sustainable. In addition, the opportunities and challenges of 3D printed formworks are evaluated in the context of other traditional and digital fabrication tools. A synthetic classification in five functional typologies is proposed and illustrated with 30 representative case studies. Finally, the article concludes with a brief reflection on the role of 3D printing in the broader context of formwork innovation and a possible outlook for this technology.

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“…Finally, in 2020, Fast Complexity, a system combining reusable binder-jet 3DPF and DDFC, was proposed for prefabricated discrete post-tensioned slab elements. 79…”

Section: Foam Jettingmentioning

confidence: 99%

Section: Reinforcementmentioning

confidence: 99%

Section: Reinforcementmentioning

confidence: 99%

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3D Printed Formwork for Concrete: State-of-the-Art, Opportunities, Challenges, and Applications

Jipa

Dillenburger

2022

3D Printing and Additive Manufacturing

Self Cite

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“…In contrast to the unstructured and weather-dependent nature of building construction sites, the controlled environment of stationary precast concrete plants provides a solid foundation for implementing additive manufacturing processes for formwork as an addition to existing production lines. 6 Significant progress has been made in the research and development of using digital fabrication techniques in the production of formwork 7 and more specifically, the production of formwork using additive processes. 8,9 However, far less has been performed to incorporate the limitations, possibilities and requirements of these production processes into the planning process of modularized concrete constructions.…”

Section: Introductionmentioning

confidence: 99%

Volumetric intersections: Modularization approaches for freeform prefab concrete construction

Stieler

Schwinn

Menges

2022

Civil Engineering Design

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The pursuit for more load‐adapted, individualized, and at the same time precise building geometries is driving innovation in digital fabrication with concrete towards greater formal freedom and higher degrees of prefabrication. This article reviews the opportunities of using three‐dimensional (3D)‐printed formwork in the context of pre‐fabricated concrete construction. It identifies the geometric specificities future planning tools need to address to incorporate the steps of modularization and fabrication into automatized planning processes from design to production. By reviewing the state‐of‐the‐art fabrication methods for nonstandard concrete geometries, we highlight possible applications and challenges for additive formwork and introduce a volumetric modeling approach to modularize surface and mesh‐based 3D design models into solid segments that can form the basis for further formwork planning.

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“…Moreover, one of the few applications of 3D printing directly used for precast components in regard to the project "Office of the Future" of Killa Design, where office boxes are realised by using a large size prefabrication (8.9 × 1.9 × 2.1 m) [19]. The 3DCP was also applied to slab prototypes in both the lightweight concrete ceiling designed at TU Graz [20] and the prefabricated concrete slabs built at ETH Zürich [21,22]. Another possible advantage of 3DCP is the concrete optimisation through efficient shapes, placing material only where functionally required.…”

Section: Introductionmentioning

confidence: 99%

Building Envelope Prefabricated with 3D Printing Technology

et al. 2021

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The Fourth Industrial Revolution represents the beginning of a profound change for the building sector. In the last decade, the perspective of shapes, materials, and construction techniques is evolving fast due to the additive manufacturing technology. On the other hand, even if the technology is growing fast and several 3D printed buildings are being developed worldwide, the potential of concrete 3D printing in building prefabrication remains unexplored. Consequently, the application of new digital fabrication technologies in the construction industry requires a redesign of the construction process and its components. This paper proposes a novel conception, design, and prototyping of a precast building envelope to be prefabricated with extrusion-based 3D concrete printing (3DCP). The new design and conception aim to fully exploit the potential of 3D printing for prefabricated components, especially in terms of dry assembly, speed of implementation, reusability, recyclability, modularity, versatility, adaptability, and sustainability. Beyond the novel conceptual design of precast elements, the research investigated the 3D printable cementitious material based on a magnesium potassium phosphate cement (MKPC), which was devised and tested to ensure good performances of the proposed component. Finally, a prototype has been realised in scale with additive manufacturing technology in order to verify the printability and to optimize the extruder path. This study leads us to believe that the combined use of prefabricated systems, construction automation, and innovative materials can decisively improve the construction industry’s sustainability in the future.

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Fast Complexity: Additive Manufacturing for Prefabricated Concrete Slabs

Cited by 15 publications

References 12 publications

3D Printed Formwork for Concrete: State-of-the-Art, Opportunities, Challenges, and Applications

3D Printed Formwork for Concrete: State-of-the-Art, Opportunities, Challenges, and Applications

Volumetric intersections: Modularization approaches for freeform prefab concrete construction

Building Envelope Prefabricated with 3D Printing Technology

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