High-Resolution Additive Formwork for Building-Scale Concrete Panels

Naboni, Roberto; Breseghello, Luca

doi:10.1007/978-3-030-49916-7_91

Cited by 11 publications

(4 citation statements)

References 12 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: Polymer Extrusionmentioning

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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“…Among emerging automation technologies for sustainable construction, Additive Manufacturing (AM) occupies a fundamental role, enabling strategic material placing . Research in AM-enhanced concrete construction is mainly distinguished between (i) indirect applications for Additive Formwork Manufacturing (AFM) to produce elements of variable complexity Breseghello 2020) and structural elements (Burger et al 2020);and (ii) direct 3D printing of construction elements (Buswell et al 2018). Within these application fields, 3D Concrete Printing (3DCP) is the main AM technique that has attracted the interest of both research (Labonotte et al 2016, Perrot 2019, Buswell et al 2020) and innovative practice (COBOD 2021, XTreeE 2021, CyBe 2021, Icon 2021, Winsun 2021.…”

Section: Global Environmental Impact Of Concrete Constructionmentioning

confidence: 99%

Lightweight 3D Printed Concrete Beams Show an Environmental Promise: A Cradle-to-Grave Comparative Life Cycle Assessment

Gislason

Bruhn

Breseghello

et al. 2022

Preprint

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Despite the increasing interest in 3D Concrete Printing (3DCP) in construction, limited research has quantitatively investigated the environmental impact that 3DCP brings. The existing Life Cycle Assessment (LCA) studies in the field can be criticized for a lack of clearly defined functional units of comparison, especially considering load-bearing structures. This paper investigates the potential environmental benefits of 3DCP over conventional concrete construction in a case study of structural beams based on a cradle-to-grave comparative LCA. Unlike in the existing LCA studies on 3DCP, this paper employs a carbonation model to account for the potential carbon offsetting from the use-stage of 3DP concrete, which showed to be significant for the results. The assessment includes three-beam designs, each analyzed for both prefabrication and on-site construction scenarios. While 3DCP generally has a higher environmental impact due to the larger quantity of cement employed in the process, the reduction of materials through shape and infill optimization results as valid design principles to reduce emissions. Results show that, while standard designed 3DCP beams perform worse than their equivalent cast beams, lightweight designs for printed beams are promising in terms of reducing the environmental impacts from construction. The paper draws recommendations for future research on material development, e.g. integration of larger aggregates and low-clinker cement, and carbonation-efficient 3DCP design of load-bearing structures, e.g. considering the environmental benefits of carbonation in the design optimization process.

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High-Resolution Additive Formwork for Building-Scale Concrete Panels

Cited by 11 publications

References 12 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

Lightweight 3D Printed Concrete Beams Show an Environmental Promise: A Cradle-to-Grave Comparative Life Cycle Assessment

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