3D-printing Parametric Concrete Unit Construction

PCU Main description this research project focuses on addressing two key challenges in concrete 3D printing:

Optimization System for Smooth Hyperbolic Surfaces in Concrete 3D Printing

Hyperbolic surfaces, known for their structural, environmental, and aesthetic value, offer significant opportunities for exploration. The ability of 3D printing technology to rapidly produce complex structures presents great potential for enhancing the performance of concrete buildings beyond traditional, monotonous forms. However, there is currently a lack of optimization systems that assist users in generating such surfaces during the design phase. Therefore, developing an optimization system for smooth hyperbolic surfaces that meet the demands of concrete 3D printing is highly meaningful.

Segmentation and Detail Optimization of Modular Units

Given the limited printing dimensions of most concrete 3D printers, modular assembly becomes an essential solution to meet the size requirements of a wide range of buildings. However, the rational segmentation of modular units and the optimization of their details—such as interfaces and lightweight topology—are crucial to the success of these assemblies.

We plan to apply post-tensioning to the units using steel cables so that the entire structure becomes a cohesive whole. To enhance stability, the distribution of the steel cables will be closely related to the stress distribution of the structure. Additionally, the segmentation of the units will adapt to the steel cable layout. We aim for our system to automatically optimize the segmentation of units based on different forms of the structure.

Designing smooth double-curved surfaces suitable for concrete 3D printing using traditional methods is challenging. Therefore, we are looking to develop an auxiliary design system to help users fit and optimize such surfaces. The key focus of this research will be ensuring smooth transitions between the curves. We aim for the system to automatically fit and optimize a smooth double-curved surface suitable for 3D printing, allowing users to simply adjust the parameters of the base form without complex manual input.

We present a process simulation tool for 3D curvature-oriented printing of self-supporting structures with additional axis base, which can predict the constraints of self-supporting during the printing process and adapt to different materials and geometries. Developed based on FEA (Finite Element Analysis) research, this simulation tool aims to optimize the final printing action by systematically predicting the printing constraints encountered during the process, thereby improving the accuracy and printable range of self-supporting printing.

3D printing concrete allows us to fabricate complex shapes for different functions, including a shelter, a staircase, etc.

By tilting the bae of the print we can print much longer over hang structures. This allows us to 3D print clay and concrete with much more flexibility.

Measuring the forces and the printing vectors in a print in real-time.

The computational model visualizes the printability and the print condition. Based on this data, we can decide how to proceed with the 3D print