How to Produce 3D Printed Formwork for Concrete Casting
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3D printed formwork is a perfect solution for casting complex geometries. The first step is to design and print the formwork. For restoration projects, it is also possible to scan existing elements to create the 3D models for the formwork.
If the formwork is larger than BigRep print volume (1m3 on the BigRep ONE, for example) then it can be printed in parts and assembled after. If needed, the 3D printed formwork can be post-processed with a variety of methods. It is also possible to combine traditional formwork for simple shapes with 3D printed formwork for complex parts. Then the concrete is cast using standard methods. Finally the formwork can be cleaned and reused.
Concrete formwork in construction can make up 40 - 60% of a total budget, especially for complex shapes such as curved concrete forms. Some designs like organic shapes, double curved surfaces, and cavities are simply not feasible to produce because they require highly skilled laborers to produce customized formwork resulting in high costs, long lead times, and material waste.
BigRep 3D printers can produce large-scale, complex formwork up to 3x faster at a fraction of the cost of traditional methods. With BigRep materials, including the new CONCRETE FORMWORK filament, you can unlock the massive benefits of 3D printed formwork.
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Bespoke Stairs, NEST STEP2-Unit
Design by Digital Building Technologies - ETH Zurich with BASF Forward AM & ROK
Fabrication System by Digital Building Technologies, ETH Zurich
3D Printed Formwork Solution by BASF Forward AM
Precast Concrete by SW Umwelttechnik
Structural Design by Walt Galmarini
Architecture by ROK
Sculpture "Vårbergs Jättar" by Xavier Veilhan and Alexis Bertrand for Stockholm Konst
Project Coordination by Atelier Xavier Veilhan / Martin Coevoet
Concrete Casting by BB Beton und Bauwaren
Additional Molds by Suppelt CNC
Installation by Herrljunga Terrazzo
Landscape Architecture and Landscaping by Nivå Landskapsarkitektur & Y2 Anläggning
Images © Veilhan, Alexis Bertrand / Bildkunst , 2020 and Xavier Vårbergs Jättar