The inherent limitation of 3D printed concrete is its requirement to be self-supporting during the printing process, which can impose geometric constraints. Addressing this challenge, a novel methodology has been developed to print concrete onto a temporary, freeform surface. This innovative approach integrates the use of a Flexible Mould, pioneered at TU Delft, with a 4-degrees-of-freedom (4 DOF) gantry printer from TU Eindhoven. The research explores various scenarios, including exclusively using 3D printing techniques and a hybrid approach that combines printing with traditional concrete casting.
The culmination of this research is the creation of a 5 square meter shell structure that demonstrates the practical application of this method. This structure was produced using a combination of partial 3D printing and casting techniques, supported by a CNC-milled mould designed to emulate the properties of a Flexible Mould. This experimental setup not only showcases the flexibility and potential of combining different manufacturing techniques but also pushes the boundaries of what can be achieved with 3D printing in construction, offering new possibilities for complex architectural forms.
