Eggshell Pavilion: a reinforced concrete structure fabricated using robotically 3D printed formwork

This paper discusses the design, fabrication, and assembly of the ‘Eggshell Pavilion’, a reinforced concrete structure fabricated using 3D printed thin shell formwork. Formworks for columns and slabs were printed from recycled plastic using a pellet extruder mounted to a robotic arm. The formworks w...

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Bibliographic Details
Published in:Construction Robotics (Online) Vol. 7; no. 2; pp. 213 - 233
Main Authors: Burger, Joris, Aejmelaeus-Lindström, Petrus, Gürel, Seyma, Niketić, Filip, Lloret-Fritschi, Ena, Flatt, Robert J., Gramazio, Fabio, Kohler, Matthias
Format: Journal Article
Language:English
Published: Cham Springer International Publishing 01.01.2023
Subjects:
Architecture
Artificial Intelligence
Control
Engineering
Mechatronics
Original Paper
Robotics
Digital concrete
Eggshell
Robotic fabrication
Formwork
3D printing
ISSN:2509-811X, 2509-8780, 2509-8780
Online Access:Get full text
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Summary:This paper discusses the design, fabrication, and assembly of the ‘Eggshell Pavilion’, a reinforced concrete structure fabricated using 3D printed thin shell formwork. Formworks for columns and slabs were printed from recycled plastic using a pellet extruder mounted to a robotic arm. The formworks were cast and demoulded, and the finished elements were assembled into a pavilion, showcasing the architectural potential of 3D printed formwork. The Eggshell Pavilion was designed and fabricated within the scope of a design studio at ETH Zurich. The structure was designed using a fully parametric design workflow that allowed for incorporating changes into the design until the fabrication. The pavilion consists of four columns and floor slabs. Each column and floor slab is reinforced with conventional reinforcing bars. Two different methods are used for casting the columns and floor slabs. The columns are cast using ‘Digital casting systems’, a method for the digitally controlled casting of fast-hardening concrete. Digital casting reduces the hydrostatic pressure exerted on the formwork to a minimum, thereby enabling the casting of tall structures with thin formwork. The floor slabs are cast with a commercially available concrete mix, as the pressure exerted on the formwork walls is lower than for the columns. In this research, 3D printed formwork is combined with traditional reinforcing, casting, and assembly methods, bringing the technology closer to an industrial application.
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ISSN:2509-811X
2509-8780
2509-8780
DOI:10.1007/s41693-023-00090-x