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Abstract

FORM{less} 1 Thin-shell concrete cast using robotically thermoformed nested molds displays the range of potential geometries and orientations achievable through this process.Robotically Thermoformed Molds for Concrete Casting 1 ABSTR ACTForm{less} focuses on the creation of complex thin-shell concrete forms using robotically thermoformed plastic molds. Typically, similar molds would be created using the vacuum forming process, producing direct replications of the pattern. Creating molds with this process is not only time-and material-intensive but also costly if customization is involved. Thin-shell concrete forms often require a labor-intensive process of manually finishing the open-face surface. The devised process of thermoforming two nested molds allows the concrete to be cast in between, with finished surfaces on both sides. Molds made with polyethylene terephthalate glycol (PETG) allow the formwork to be reused and recycled.The research and fabrication work include the development of heating elements and the creation of the robotic process for forming the PETG. The PETG is manipulated via a robotic arm, with a custom magnetic end effector. The integration of robotics not only enables precision for manufacturing but also allows for replicability with unrestricted threedimensional deformation. The repeatable process allows for rapid prototyping and geometric customization. Design options are then simulated computationally using SuperMatterTools, enabling further design exploration of this process without the need for extensive physical prototyping. This research aims to develop a process that allows for the creation of complex geometries while reducing the amount of material waste used for concrete casting. The novelty of the process created by dynamically forming PETG allows for quick production of formwork that is both customizable and replicable. This method of creating double-sided building components is simulated at various scales of implementation.