Fused Deposition Modelling Formworks for Complex Concrete Constructions

Naboni, Roberto; Breseghello, Luca

doi:10.5151/sigradi2018-1648

Cited by 14 publications

(8 citation statements)

References 15 publications

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“…In particular, we build upon a previously demonstrated technique by the authors for AFM that employs Fused Deposition Modelling (FDM) [20]. This was successfully applied in a multitude of projects with production batches characterised by high-geometrical complexity [21][22][23]. Compared to the State-of-Art and commercially available methods based on subtractive fabrication [24,25], our method supports: (i) extreme morphological and topological complexity; (i) the precise parallel execution of concrete casting and complex steel welding; (iii) unprecedented geometry resolution and integration of functional features; (iv) full and easy disassembly of the mould parts and possibility for reuse and recycle; (v) no need for manual post-processing of the mould elements.…”

Section: Research Aim and Original Approachmentioning

confidence: 99%

Complex modelling automation for 3D polyhedral structures built with additive formwork manufacturing

Naboni

Zomparelli

2023

Archit. Struct. Constr.

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Polyhedral structures are a fascinating and efficient case of structural virtuosity. However, their adoption to date has been limited because of geometrical, structural and fabrication complexities. This paper introduces a modelling pipeline to provide a rigorous -yet practical-approach to the challenges linked to the realisation of 3D polyhedral structures, from early-stage design to fabrication. A custom-developed modelling add-on is utilised for reconstructing the underlying topology of 3D polyhedral structures and implementing a component-based approach for the design development. Concurrently, an innovative digital fabrication strategy based on Additive Formwork Manufacturing is presented, with a detailed description of the process and illustration of a fully-functional physical prototype. Methodological and software developments are applied to the fabrication experiments where the approach is tested with in-depth design and construction insights. The approach is ultimately discussed for the development of real-world structures and in light of the potential adoption by non-expert computational designers.

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Section: Research Aim and Original Approachmentioning

confidence: 99%

Complex modelling automation for 3D polyhedral structures built with additive formwork manufacturing

Naboni

Zomparelli

2023

Archit. Struct. Constr.

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“…65 Another recent project from CREATE, University of Southern Denmark, investigated the fabrication of informed textures with polymer 3DPF and measured the deviations of the resulting concrete parts and formworks compared to the designed digital model. 66 …”

Section: State-of-the-artmentioning

confidence: 99%

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

Jipa

Dillenburger

2022

3D Printing and Additive Manufacturing

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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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“…The large mass of the mold pieces prevented it from being very flexible, and thus prevented the cast object from being removed from the mold without a significant overpour. The design was revisited after being informed by a few other studies into thin-walled formwork (Naboni et al, 2018), and a thin-walled mold iteration was printed that was able to produce the delicate panels without breaking them during the demolding process (Fig. 4).…”

Section: Panel A: From Design To Fabricationmentioning

confidence: 99%

The Design and Fabrication of Variable Façade Panel Systems

Theisen¹,

Emami²

2021

Blucher Design Proceedings

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This study explores how alternative molding methods can be utilized to construct a variety of prefabricated volumetric concrete panels for façades from a single digitally fabricated mold. First, precedents were studied and panel variability was classified into ornamental, geometric, or assembly categories. Then, a molding method was proposed that improves upon traditional processes. Traditionally, geometrically varied façade panels are realized through creating a single mold for every variant, which is inefficient and wasteful. The proposed method allows for reusability of a singular mold which can fabricate variated panels through utilizing interchangeable mold inserts. This proposal was tested on a small scale through creating rapid iterations of molds fabricated with Stereolithography (SLA) printing.Emerging big area additive manufacturing (BAAM) technology allows for the proposed methods to be utilized at the industrial scale where they can reduce the cost, labor, and time of fabricating varied concrete panels while also creating complex geometries.

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Fused Deposition Modelling Formworks for Complex Concrete Constructions

Abstract: xxii congresso da sociedade iberoamericana de gráfica digital 22th conference of the iberoamerican society of digital graphics 07|08|09|novembro|2018 iau usp | são carlos | sp br

Cited by 14 publications

References 15 publications

Complex modelling automation for 3D polyhedral structures built with additive formwork manufacturing

Complex modelling automation for 3D polyhedral structures built with additive formwork manufacturing

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

The Design and Fabrication of Variable Façade Panel Systems

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