Skip to content

Digital Fabrication with Cement-Based Materials (2022-01)

Process Classification and Case Studies

10.1007/978-3-030-90535-4_2

 Buswell Richard,  Bos Freek,  da Silva Wilson,  Hack Norman,  Kloft Harald,  Lowke Dirk,  Freund Niklas,  Fromm Asko,  Dini Enrico,  Wangler Timothy,  Lloret-Fritschi Ena,  Schipper Roel,  Mechtcherine Viktor,  Perrot Arnaud, Vasilić Ksenija,  Roussel Nicolas
Contribution - Digital Fabrication with Cement-Based Materials, pp. 11-48

Abstract

The need for methods for forming concrete has existed for as long as concrete has been used in constructing the built environment. Creating flat, rectilinear formers have traditionally been the cost and time efficient default for the majority of applications. The desire for greater design freedom and the drive to automate construction manufacturing is providing a platform for the continued development of a family of processes called Digital Fabrication with Concrete (DFC) technologies. DFC technologies are many and varied. Much of the material science theory is common, but the process steps vary significantly between methods, creating challenges as we look towards performance comparison and standardisation. Presented here is a framework to help identify and describe process differences and a showcase of DFC application case studies that explain the processes behind a sub-set of the technologies available.

36 References

  1. Asprone Domenico, Menna Costantino, Bos Freek, Salet Theo et al. (2018-06)
    Rethinking Reinforcement for Digital Fabrication with Concrete
  2. Bos Freek, Ahmed Zeeshan, Jutinov Evgeniy, Salet Theo (2017-11)
    Experimental Exploration of Metal-Cable as Reinforcement in 3D Printed Concrete
  3. Bos Freek, Ahmed Zeeshan, Wolfs Robert, Salet Theo (2017-06)
    3D Printing Concrete with Reinforcement
  4. Bos Freek, Wolfs Robert, Ahmed Zeeshan, Salet Theo (2016-08)
    Additive Manufacturing of Concrete in Construction:
    Potentials and Challenges of 3D Concrete Printing
  5. Buchli Jonas, Giftthaler Markus, Kumar Nitish, Lussi Manuel et al. (2018-07)
    Digital In-Situ Fabrication:
    Challenges and Opportunities for Robotic In-Situ Fabrication in Architecture, Construction, and Beyond
  6. Buswell Richard, Silva Wilson, Bos Freek, Schipper Roel et al. (2020-05)
    A Process Classification Framework for Defining and Describing Digital Fabrication with Concrete
  7. Buswell Richard, Silva Wilson, Jones Scott, Dirrenberger Justin (2018-06)
    3D Printing Using Concrete-Extrusion:
    A Roadmap for Research
  8. Gosselin Clément, Duballet Romain, Roux Philippe, Gaudillière-Jami Nadja et al. (2016-03)
    Large-Scale 3D Printing of Ultra-High-Performance Concrete:
    A New Processing Route for Architects and Builders
  9. Hack Norman, Dörfler Kathrin, Walzer Alexander, Wangler Timothy et al. (2020-03)
    Structural Stay-in-Place Formwork for Robotic In-Situ Fabrication of Non-Standard Concrete Structures:
    A Real-Scale Architectural Demonstrator
  10. Hack Norman, Lauer Willi (2014-04)
    Mesh Mould:
    Robotically Fabricated Spatial Meshes as Reinforced Concrete Formwork
  11. Hack Norman, Lauer Willi, Langenberg Silke, Gramazio Fabio et al. (2013-09)
    Overcoming Repetition:
    Robotic Fabrication Processes at a Large-Scale
  12. Khoshnevis Behrokh, Hwang Dooil, Yao Ke, Yeh Zhenghao (2006-05)
    Mega-Scale Fabrication by Contour Crafting
  13. Kloft Harald, Krauss Hans-Werner, Hack Norman, Herrmann Eric et al. (2020-05)
    Influence of Process Parameters on the Inter-Layer Bond Strength of Concrete Elements Additive Manufactured by Shotcrete 3D Printing
  14. Labonnote Nathalie, Rønnquist Anders, Manum Bendik, Rüther Petra (2016-09)
    Additive Construction:
    State of the Art, Challenges and Opportunities
  15. Le Thanh, Austin Simon, Lim Sungwoo, Buswell Richard et al. (2012-01)
    Hardened Properties of High-Performance Printing Concrete
  16. Le Thanh, Austin Simon, Lim Sungwoo, Buswell Richard et al. (2012-01)
    Mix-Design and Fresh Properties for High-Performance Printing Concrete
  17. Lim Sungwoo, Buswell Richard, Le Thanh, Austin Simon et al. (2011-07)
    Developments in Construction-Scale Additive Manufacturing Processes
  18. Lim Sungwoo, Buswell Richard, Valentine Philip, Piker Daniel et al. (2016-06)
    Modelling Curved-Layered Printing Paths for Fabricating Large-Scale Construction Components
  19. Lloret-Fritschi Ena, Reiter Lex, Wangler Timothy, Gramazio Fabio et al. (2017-03)
    Smart Dynamic Casting:
    Slipforming with Flexible Formwork
  20. Lloret-Fritschi Ena, Scotto Fabio, Gramazio Fabio, Kohler Matthias et al. (2018-09)
    Challenges of Real-Scale Production with Smart Dynamic Casting
  21. Lloret-Fritschi Ena, Shahab Amir, Linus Mettler, Flatt Robert et al. (2014-03)
    Complex Concrete Structures:
    Merging Existing Casting Techniques with Digital Fabrication
  22. Lowke Dirk, Dini Enrico, Perrot Arnaud, Weger Daniel et al. (2018-07)
    Particle-Bed 3D Printing in Concrete Construction:
    Possibilities and Challenges
  23. Marchon Delphine, Kawashima Shiho, Bessaies-Bey Hela, Mantellato Sara et al. (2018-05)
    Hydration- and Rheology-Control of Concrete for Digital Fabrication:
    Potential Admixtures and Cement-Chemistry
  24. Mechtcherine Viktor, Nerella Venkatesh, Will Frank, Näther Mathias et al. (2019-08)
    Large-Scale Digital Concrete Construction:
    CONPrint3D Concept for On-Site, Monolithic 3D Printing
  25. Nerella Venkatesh, Hempel Simone, Mechtcherine Viktor (2019-02)
    Effects of Layer-Interface Properties on Mechanical Performance of Concrete Elements Produced by Extrusion-Based 3D Printing
  26. Neudecker Stefan, Bruns Christopher, Gerbers Roman, Heyn Jakob et al. (2016-05)
    A New Robotic Spray Technology for Generative Manufacturing of Complex Concrete-Structures without Formwork
  27. Pierre Alexandre, Weger Daniel, Perrot Arnaud, Lowke Dirk (2018-01)
    Penetration of Cement-Pastes into Sand-Packings During 3D Printing:
    Analytical and Experimental Study
  28. Reiter Lex, Wangler Timothy, Roussel Nicolas, Flatt Robert (2018-06)
    The Role of Early-Age Structural Build-Up in Digital Fabrication with Concrete
  29. Roussel Nicolas (2018-05)
    Rheological Requirements for Printable Concretes
  30. Salet Theo, Ahmed Zeeshan, Bos Freek, Laagland Hans (2018-05)
    Design of a 3D Printed Concrete Bridge by Testing
  31. Tay Yi, Ting Guan, Qian Ye, Panda Biranchi et al. (2018-07)
    Time-Gap-Effect on Bond Strength of 3D Printed Concrete
  32. Wolfs Robert, Bos Freek, Salet Theo (2018-06)
    Correlation Between Destructive Compression Tests and Non-Destructive Ultrasonic Measurements on Early-Age 3D Printed Concrete
  33. Wolfs Robert, Bos Freek, Salet Theo (2018-02)
    Early-Age Mechanical Behaviour of 3D Printed Concrete:
    Numerical Modelling and Experimental Testing
  34. Wolfs Robert, Bos Freek, Salet Theo (2019-03)
    Hardened Properties of 3D Printed Concrete:
    The Influence of Process Parameters on Inter-Layer Adhesion
  35. Wolfs Robert, Bos Freek, Strien Emiel, Salet Theo (2017-06)
    A Real-Time Height Measurement and Feedback System for 3D Concrete Printing
  36. Wolfs Robert, Suiker Akke (2019-06)
    Structural Failure During Extrusion-Based 3D Printing Processes

24 Citations

  1. Barry Mamadou, Jacquet Yohan, Perrot Arnaud (2025-10)
    Pocket Vane and Penetrometer as Quality Control Tool for Extrusion 3D Concrete Printing
  2. Tang Boyang, Yan Jiachuan, Han Xiaoyu, Lin Yini et al. (2025-05)
    Mechanical Properties of Extrusion-Based 3D-Printed Concrete Considering the Thickness of the Printed Layer and Printing Time Interval
  3. Nadi Mouad, Majdoubi Hicham, Haddaji Younesse, Bili Oumaima et al. (2025-01)
    Digital Fabrication Processes for Cementitious Materials Using Three-Dimensional 3D Printing Technologies
  4. Perrot Arnaud, Jacquet Yohan, Amziane Sofiane (2025-01)
    3D Concrete Printing
  5. Pierre Alexandre, Perrot Arnaud (2025-01)
    Alternative Printing-Methods for Cementitious Materials
  6. Reißig Silvia, Herdan Annika, Mechtcherine Viktor (2024-09)
    Rheological Behavior of Steel-Fiber-Reinforced Concrete in the Context of Additive Manufacturing
  7. David Martin, Dröder Klaus (2024-09)
    Robot-Guided End Effector for an Automated Finishing of Concrete Free-Form Surfaces
  8. Lowke Dirk, Anton Ana-Maria, Buswell Richard, Jenny Ercan et al. (2024-09)
    Digital Fabrication with Concrete Beyond Horizontal Planar Layers
  9. Ostovari Shadi, Shayani Hooman (2024-06)
    Simulation and Analysis of Automated Generalised Interleaved Layered Execution (AGILE) Process for Concrete Shell-Structures
  10. Zeng Jun-Jie, Yan Zitong, Jiang Yuan, Li Pei-Lin (2024-02)
    3D Printing of FRP Grid and Bar Reinforcement for Reinforced Concrete Plates:
    Development and Effectiveness
  11. Freund Niklas, David Martin, Böhler David, Mai (née Dressler) Inka et al. (2023-12)
    Shotcrete 3D Printing:
    Interaction of Nozzle Geometry, Homogeneity and Hardened Concrete Properties
  12. Freund Niklas, Dörrie Robin, David Martin, Kloft Harald et al. (2023-10)
    Enclosing Reinforcement Structures in Shotcrete 3D Printing:
    The Effect of Reinforcement Geometry and Accelerator Dosage on the Formation of Voids
  13. Kurniati Eka, Kim Heejeong (2023-10)
    Utilizing Industrial Byproducts for Sustainable Three-Dimensional-Printed Infrastructure Applications:
    A Comprehensive Review
  14. David Martin, Freund Niklas, Dröder Klaus, Lowke Dirk (2023-09)
    The Effects of Nozzle-Diameter and Length on the Resulting Strand Properties for Shotcrete 3D Printing
  15. Zeng Jun-Jie, Li Pei-Lin, Yan Zitong, Zhou Jie-Kai et al. (2023-08)
    Behavior of 3D Printed HPC Plates with FRP-Grid-Reinforcement Under Bending
  16. Placzek Gerrit, Schwerdtner Patrick (2023-07)
    Concrete Additive Manufacturing in Construction:
    Integration Based on Component-Related Fabrication-Strategies
  17. Breseghello Luca, Hajikarimian Hamed, Jørgensen Henrik, Naboni Roberto (2023-07)
    3DLightBeam+:
    Design, Simulation, and Testing of Carbon-Efficient Reinforced 3D Concrete Printed Beams
  18. Hass Lauri, Bos Freek, Salet Theo (2022-09)
    Characterizing the Bond Properties of Automatically Placed Helical Reinforcement in 3D Printed Concrete
  19. Buswell Richard (2022-06)
    CCR Digital Concrete 2022 SI:
    Editorial
  20. Breseghello Luca, Naboni Roberto (2022-05)
    Tool-Path -Based Design for 3D Concrete Printing of Carbon-Efficient Architectural Structures
  21. Buswell Richard, Xu Jie, Becker Daniel, Dobrzanski James et al. (2022-04)
    Geometric Quality Assurance for 3D Concrete Printing and Hybrid Construction Manufacturing Using a Standardised Test Part for Benchmarking Capability
  22. Bos Freek, Menna Costantino, Pradena Mauricio, Kreiger Eric et al. (2022-03)
    The Realities of Additively Manufactured Concrete Structures in Practice
  23. Lowke Dirk, Mai (née Dressler) Inka, Keita Emmanuel, Perrot Arnaud et al. (2022-02)
    Material-Process Interactions in Particle-Bed 3D Printing and the Underlying Physics
  24. Vasilić Ksenija, Hack Norman, Kloft Harald, Lowke Dirk et al. (2022-01)
    Digitale Fertigung im Betonbau

BibTeX
@inproceedings{busw_bos_silv_hack.2022.DFwCBM,
  author            = "Richard A. Buswell and Freek Paul Bos and Wilson Ricardo Leal da Silva and Norman Peter Hack and Harald Kloft and Dirk Lowke and Niklas Freund and Asko Fromm and Enrico Dini and Timothy Paul Wangler and Ena Lloret-Fritschi and Roel H. Schipper and Viktor Mechtcherine and Arnaud Perrot and Ksenija Vasilić and Nicolas Roussel",
  title             = "Digital Fabrication with Cement-Based Materials: Process Classification and Case Studies",
  doi               = "10.1007/978-3-030-90535-4_2",
  year              = "2022",
  volume            = "36",
  pages             = "11--48",
  booktitle         = "Digital Fabrication with Cement-Based Materials",
  editor            = "Nicolas Roussel and Dirk Lowke",
}
Formatted Citation

R. A. Buswell, “Digital Fabrication with Cement-Based Materials: Process Classification and Case Studies”, in Digital Fabrication with Cement-Based Materials, 2022, vol. 36, pp. 11–48. doi: 10.1007/978-3-030-90535-4_2.

Buswell, Richard A., Freek Paul Bos, Wilson Ricardo Leal da Silva, Norman Peter Hack, Harald Kloft, Dirk Lowke, Niklas Freund, et al.. “Digital Fabrication with Cement-Based Materials: Process Classification and Case Studies”. In Digital Fabrication with Cement-Based Materials, edited by Nicolas Roussel and Dirk Lowke, 36:11–48, 2022. https://doi.org/10.1007/978-3-030-90535-4_2.