Conformal 3D Printing on Bending-Active Formwork (2025-10)¶

This study introduces a novel methodological framework that combines bending-active structures with conformal 3D printing to address current limitations in architectural-scale additive manufacturing. Traditional horizontal slicing and planar layer deposition present inherent constraints for fabricating large-span elements such as roofs and floor slabs, while conventional approaches to curved forms typically require resource-intensive formwork. We propose an integrated approach that utilizes bending-active structures as material-efficient substrates for 3D printing, potentially serving dual roles as both formwork and supplementary reinforcement. The methodology incorporates a multi-axis robotic platform alongside preliminary design, software, and hardware adaptations to enable material deposition that follows structural force vectors. Through initial experimental studies at various scales, we examine the fundamental aspects of this approach – including material testing, formwork registration, and toolpath adaptation – establishing a foundation for further exploration. This paper presents the conceptual framework and preliminary findings, while specific technical aspects such as toolpath generation algorithms and structural simulations are addressed in a companion paper. By introducing this methodology, we aim to contribute to the discourse on more sustainable fabrication techniques for wide-spanning architectural elements with reduced material consumption and environmental impact.