Fabrication-Aware Structural Form-Finding for Additive Manufacturing (2025-07)¶

This paper presents an approach for designing material-efficient, self-supporting vaulted structures using extrusion-based 3D printing via formwork-free robotic fabrication. An equilibrium-based structural form-finding method is introduced that directly couples the global geometry with the print path to simultaneously generate the overall structure and print path layer by layer. By incorporating structural, material, and fabrication constraints into the form-finding routine at both the final and layer-wise fabrication stages, the design space is strategically confined to ensure fabrication with self-supporting layers. As proof of concept, design studies using the proposed method are presented. The developed form-finding routine offers precise control over the fabrication process, allowing for optimizing material efficiency and reducing waste through formwork-free techniques, thereby addressing key challenges in contemporary construction. The design approach demonstrates significant potential for future research, including applications to non-planar print path configurations and large-scale prototypes, although identifying specific material properties requires additional investigation.