Exploring 3D Concrete Printing on Circular Substructures for Circular Futures

In the past decade additive manufacturing has gained an incredible traction in the construction industry. The field of 3D concrete printing (3DCP) has advanced significantly, leading to commercially viable housing projects. The use of concrete represents a challenge because of its environmental impact and CO2 footprint. Due to its material properties, structural capacity and ability to take on complex geometries with relative ease, concrete is and will remain for the foreseeable future a key construction material. The framework required for casting concrete, in particular non-orthogonal geometries, is in itself wasteful, not reusable, contributing to its negative environmental impact. Non-standard, complex geometries generally require the use of moulds and subsystems to be produced, leading to wasteful, material-intense manufacturing processes, with high carbon footprints.
This research proposal bypasses the use of wasteful scaffolding and moulds, by exploring 3D printing with concrete on reusable substructures made of sand, clay or aggregate. Optimised material depositing strategies for 3DCP will be explored, by making use of algorithmic structural optimisation. This way, material is deposited only where structurally needed, allowing for further reduction of raw-material use. This collaboration between Neutelings Riedijk Architects, Vertico and the Architectural Design and Engineering Chair of the TU Eindhoven, investigates full-scale additive manufacturing of spatially complex 3D-concrete printed components using multi-material support systems (clay, sand and aggregates). These materials can be easily shaped multiple times into substrates with complex geometries, without generating material waste.
The 3D concrete printed full-scale prototypes can be used as lightweight façade elements, screens or spatial dividers. To generate waterproof components, the cavities of the extruded lattices can be filled up with lightweight clay or cement.
This process allows for the exploration of new aesthetic, creative and circular possibilities, complex geometries and new material expressions in architecture and construction, while reducing raw-material use and waste.