From Smart Dynamic Casting to a growing family of Digital Casting Systems

Lloret-Fritschi, Ena; Wangler, Timothy; Gebhard, Lukas; Mata‐Falcón, Jaime; Mantellato, Sara; Scotto, Fabio; Burger, Joris; Szabó, Anna; Ruffray, Nicolas; Reiter, Lex; Boscaro, Federica; Kaufmann, Walter; Köhler, Matthias; Gramazio, Fabio; Flatt, Robert J.

doi:10.1016/j.cemconres.2020.106071

Cited by 82 publications

(44 citation statements)

References 22 publications

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“…Other process exploiting such casting systems have been proposed and may generally be referred to as Digital Casting Technologies. 22 In Eggshell, by exploiting the casting material chemistry and processing, it becomes possible to use a thin, singlelayered shell as formwork without any additional supports or counter-pressure material. Further, by printing the formwork, instead of actuating it as in SDC, a much wider range of geometries can be produced without losing the advantage of being able to include traditional reinforcement in structural building components.…”

Section: Eggshellmentioning

confidence: 99%

Eggshell: Ultra-Thin Three-Dimensional Printed Formwork for Concrete Structures

Burger

Lloret-Fritschi

Scotto

et al. 2020

3D Printing and Additive Manufacturing

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Concrete is a material favored by architects and builders alike due to its high structural strength and its ability to take almost any form. However, to shape concrete structures, heavy-duty formwork is usually necessary to support the fresh concrete while curing. To expand geometrical freedom, three-dimensional (3D) printed concrete formwork has emerged as a field of research. This article presents one possible application, a novel fabrication process that combines large-scale robotic fused deposition modeling 3D printing with simultaneous casting of a fast-hardening, set-on-demand concrete. This fabrication process, known as ''Eggshell,'' enables the production of nonstandard concrete structures in a material-efficient process. By casting a fast-hardening concrete in a continuous process, lateral pressure exerted by the fresh concrete is kept to a minimum. In this way, a 1.5-mm-thin thermoplastic shell can be used as a formwork, without any additional support. Geometries of different scales are tested in this article to evaluate the feasibility of the Eggshell fabrication process in an architectural context. An array of printing materials are also tested, and several different reinforcement concepts are analyzed. The findings are used to produce a full-scale architectural demonstrator project. This article shows that a wide range of concrete geometries can be produced in a material-efficient fabrication process, paving the way toward mass customization and structural optimization within concrete architecture.

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Section: Eggshellmentioning

confidence: 99%

Eggshell: Ultra-Thin Three-Dimensional Printed Formwork for Concrete Structures

Burger

Lloret-Fritschi

Scotto

et al. 2020

3D Printing and Additive Manufacturing

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“…Eggshell, based on Smart Dynamic Casting [24], is a fabrication process in which a thin formwork is robotically 3D printed also using the set-on demand processing strategy, with the difference of using self-compacting concrete that flows into a thin formwork [25,26]. By casting this fast-hardening concrete, lateral pressure exerted by the concrete is kept to a minimum.…”

Section: Digital Fabrication With Concrete At Eth Zurichmentioning

confidence: 99%

Aligned Interlayer Fibre Reinforcement and Post-tensioning as a Reinforcement Strategy for Digital Fabrication

et al. 2020

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Digital Fabrication with Concrete (DFC) brings many new possibilities for the design and production of concrete structures, promising to revolutionise the concrete construction industry. While technological and material challenges have already been overcome to a large extent, there is still a lack of sufficiently mature reinforcement solutions. Therefore, most digital technologies encounter difficulties in producing load-bearing concrete members. Fibre reinforced concrete (FRC) is one of the most promising reinforcing strategies for DFC due to its capability for producing complex geometries. In conventional FRC, the fibres are dispersed randomly in the concrete matrix; for DFC applications this (i) forces to re-engineer the concrete processing (pumpability and rheology), and (ii) requires using very short and expensive fibres due to pumpability constraints. This paper presents a new reinforcement strategy for using FRC in layered DFC technologies that overcomes the stated limitations of conventional FRC. It consists in adding fibres right after the deposition of each layer of concrete in a controlled amount and orientation and providing a posttensioning reinforcement in the perpendicular direction. The mechanical behaviour, as well as the potential and first implementation steps in the Concrete Extrusion 3D Printing and Eggshell technologies under development at ETH Zurich, are discussed. The mechanical results show a significant increase in tensile resistance of the aligned interlayer fibre reinforcement compared to conventional FRC. However, for large-scale applications, the main loads still need to be carried by post-tensioning reinforcement.

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“…Concrete used in 3D printing is passed through the stages of pumping, extrusion through the nozzle, and accurate deposition in the successive layers to achieve a three-dimensional object, as shown in Figure 1 . Extruded concrete supports self-weight and retains its shape without the use of formwork and bonds with the subsequent layers [ 3 , 4 , 5 ]. This layer-by-layer concrete extrusion is also called concrete additive manufacturing and concrete ink printing.…”

Section: Introductionmentioning

confidence: 99%

3D Concrete Printing: A Systematic Review of Rheology, Mix Designs, Mechanical, Microstructural, and Durability Characteristics

2021

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This paper provides a state-of-the-art report on the up-to-date research on the emerging 3D concrete printing technology from the concrete materials perspective. It reviews the recent research focused on understanding and characterizing the rheological necessities of the concrete printing process and discusses how the researchers are tailoring compatible mix proportions for the 3D concrete printing process by using eco-friendly binders, waste aggregates, chemical admixtures, and nano-additives. This paper systematically evaluates anisotropic behavior in the mechanical properties of printed concrete and establishes an order for anisotropic behavior in the compressive, flexural, and tensile strengths along three different axes (X, Y, and Z axes) of printed concrete. It evaluates the ratio of flexural strength to the compressive strength of printed concrete along the above three axes. This article explains the influence of variation of printing process parameters on the mechanical properties and discusses reinforcement approaches used for increasing structural performance. The microstructure at the interface of adjacent layers and also at the interface of the reinforcement-cement matrix is discussed. The recent research on the durability performance of printed concrete is critically discussed and future research needs for 3D concrete printing are identified in this paper.

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From Smart Dynamic Casting to a growing family of Digital Casting Systems

Cited by 82 publications

References 22 publications

Eggshell: Ultra-Thin Three-Dimensional Printed Formwork for Concrete Structures

Eggshell: Ultra-Thin Three-Dimensional Printed Formwork for Concrete Structures

Aligned Interlayer Fibre Reinforcement and Post-tensioning as a Reinforcement Strategy for Digital Fabrication

3D Concrete Printing: A Systematic Review of Rheology, Mix Designs, Mechanical, Microstructural, and Durability Characteristics

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