Digital Fabrication with Concrete Beyond Horizontal Planar Layers (2024-09)¶

Digital fabrication technologies, such as 3D concrete printing, are currently making their way into the construction industry. The primary focus in this field is often on the depositing processes, such as extrusion 3D concrete printing, where material is typically applied in horizontal planar layers. This area has seen substantial progress in recent years. However, numerous research and development projects are specifically targeting the additive manufacturing of unreinforced raw concrete components. When implementing these technologies in practice, it has become clear that additional processes, such as fully automated process-parallel reinforcement integration, application of cover layers and formative and subtractive post-processing of the components, are essential for successful application. In addition, by varying the orientation, characteristics and arrangement of the layers, new shapes and functions can be realised. Examples include angled layer orientation for producing vaulted geometries without support structures, as well as non-planar layer formation for complex component geometries or assembly joints. Moreover, alternative innovative manufacturing processes, such as KnitCrete, Smart Dynamic Casting or Injection 3D Printing, reveal new potential for the application of digital manufacturing technologies in the construction industry. This article aims to demonstrate the possibilities offered by digital fabrication with concrete beyond the stacking of horizontal planar layers, and how these technologies can complement and expand a future digital fabrication strategy in the construction industry.