Integrated Fiber Forms – Functionally Integrated Slab Systems through Additive Manufacturing and Natural Fiber Reinforcement

Today’s structural floor systems are labour-intensive to install and constrained to prismatic shapes, relying on formwork that leads to material waste and elevated carbon emissions. This research introduces a particlebed 3D-printed, stay-in-place formwork produced from upcycled wood-aggregate. The formwork defines the geometry of the slab and also sequesters biogenic carbon, provides acoustic dampening, and enables complex, performance-optimised geometries. Instead of conventional steel reinforcement, robotically wound natural fibre cords are applied and anchored to dedicated winding points integrated directly into the printed formwork. Combined with cast geopolymer concrete, this approach eliminates the risk of corrosion and significantly reduces embodied carbon. Because the formwork remains in place, no dismantling or disposal is required, resulting in substantial reductions in labour and construction waste. The system’s topology-optimised geometry accommodates embedded utility conduits, removing the need for suspended ceilings and maximising usable space. The result is a lightweight, trade-friendly floor system that is both functionally and environmentally advanced. Its feasibility has been demonstrated at full architectural scale through a 1:1 prototype.