This research presents an alternative approach to constructing compression-only structures by introducing an innovative in-situ construction approach. This approach involves assembling lightweight 3D-printed plastic formworks into a compression-only configuration for the casting of concrete. To overcome the issue of hydrostatic pressure, instead of casting the entire structure at once, this research adopts sequentially casting concrete. This is achieved through developing: 1) a new construction method based on the assembly of lightweight 3D printed plastic formwork in compression-only form, which is then sequentially cast with concrete in place; 2) an integrative formwork system informed by structural and

This research aims to revolutionizes the process of fabricating free-form surfaces and investigate the  bed usage in printing doubly curved clay panels. The development process of the printing bed involved two main systems that would coexist and work together flawlessly: (1) a printing surface; (2) a grid of linear actuators, which required a balance between it’s form and function. The printing surface of the bed is made of a composite material consisting of a honeycomb TPU grid that reinforces the silicon surface cast on it. With 49 independent linear actuators, the bed surface’s shape and curvature

Shell Wall demonstrator is the first lightweight, structurally reinforced freeform concrete wall ever 3D printed. This innovative wall system features a geometry optimized to support its load case, with material distributed in a hierarchical grid of curved ribs ranging in diameter from 65 to 150 millimeters. The non-load-bearing areas between these ribs are just 6.5 to 8 centimeters deep, enabling the sandwiching of insulation between two concrete shells that are only 2.5 millimeters thick. The fields of concrete between the ribs are domed to increase stability and minimize material usage. Shell Wall weighs only 160 kilograms