Large-Scale Additive Manufacturing of Ultra-High-Performance Concrete of Integrated Formwork for Truss-Shaped Pillars

In the present paper a new additive manufacturing processing route is introduced to produce ultra-high-performance concrete complex architectonic elements, by printing integrated formwork. Interdisciplinary work involving material science, computation, robotics, architecture and design resulted in the development of an innovative way of 3D printing cementitious materials. The 3D printing process involved is based on a FDM-like technique, in the sense that a material is deposited layer by layer through an extrusion printhead mounted on a 6-axis robotic arm. An architectural application is used as a case-study to demonstrate the potentialities of the technology. Along with the detailed description of the design and construction process, a description of the responsibilities and their distribution amongst the stakeholders involved in the project is given. The steps taken to include the 3D printed element in an authorized regulatory context are presented as well. The structural elements produced constitute some of the largest 3D printed concrete parts available until now. Multi-functionality was enabled for structural elements by taking advantage of the complex geometry which can be achieved using our technology for large-scale additive manufacturing. The proposed process succeeds in solving several of the current issues problems that can be found in the production of 3D printed architectural features for an AEC industrial context and therefore suggests an immediately viable route for industry assimilation.