Robotic 3D Printing of Integrative Formwork

This research investigates robotic fused deposition modeling (FDM)  for the prefabrication of large-scale, lightweight, and ready-to-cast freeform formwork to minimize material waste, labor, and errors in the construction process while increasing the speed of production and economic viability of casting non-standard concrete elements. This is achieved through the development of a digital design-to-production workflow for concrete formwork. All functions that are needed in the final product, an integrally insulated steel-reinforced concrete wall, and the process for a successful cast, are fully integrated into the formwork system. A parametric model for integrated structural ribbing is developed and verified using finite element analysis. A case study is presented, which showcases the fully integrated system in the production of a 2.4 m tall x 2.0 m curved concrete wall. This research demonstrates the potential for large-scale additive manufacturing to enable the efficient production of non-standard concrete formwork.