From Digital to Real (2025-04)¶

Optimised and Functionally Integrated Shotcrete 3D Printing Elements for Multi-Storey Structures

Dörrie Robin, Gantner Stefan, Amiri Fatemeh, Lachmayer Lukas, David Martin, Rothe Tom, Freund Niklas, Nouman Ahmad, Mawas Karam, Oztoprak Oguz, Rennen Philipp, Ekanayaka Virama, Hürkamp André, Kollmannsberger Stefan, Hühne Christian, Raatz Annika, Dröder Klaus, Lowke Dirk, Hack Norman, Kloft Harald
Journal Article - Buildings, Vol. 15, Iss. 9, No. 1461

Abstract

The construction industry is facing a dual challenge: an increasing demand for new buildings on the one hand and the urgent need to drastically reduce emissions and waste on the other. One promising field of research to face these challenges comprises additive manufacturing (AM) technologies. Through these advanced methods, digital workflows between design and fabrication can be implemented to optimise the form and structure, unlocking new architectural freedom while ensuring sustainability and efficiency. However, to drive this transformation in construction, the new technologies must be investigated in large-scale applications. One of these fast-emerging AM techniques is Shotcrete 3D Printing (SC3DP). The present research documents the 1:1 scale manufacturing process, from digital to real, of a building section utilising SC3DP. A workflow and production steps, spanning from design over manufacturing to assembly, are introduced. The architectural design, reinforced by computational methods, was iteratively refined to adapt to manufacturing constraints. The paper also emphasises the importance of a digital twin in ensuring seamless data integration and real-time adjustments during construction. By incorporating reinforcement techniques such as short rebar insertion and robotic fibre winding, this study demonstrates the structural capabilities achievable with SC3DP. In summary, the implementation of comprehensive digital workflows utilising computational design, automated data acquisition and data flow, as well as robotic fabrication is presented to demonstrate the potential of AM methods in construction. Furthermore, this paper provides a perspective on potential future research paths and opportunities inherent in leveraging the innovative SC3DP technique.

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51 References

3 Citations

BibTeX

@article{dorr_gant_amir_lach.2025.FDtR,
  author            = "Robin Dörrie and Stefan Gantner and Fatemeh Salehi Amiri and Lukas Lachmayer and Martin David and Tom Niklas Rothe and Niklas Freund and Ahmad Saleem Nouman and Karam Mawas and Oguz Oztoprak and Philipp Rennen and Virama Ekanayaka and André Hürkamp and Stefan Kollmannsberger and Christian Hühne and Annika Raatz and Klaus Dröder and Dirk Lowke and Norman Peter Hack and Harald Kloft",
  title             = "From Digital to Real: Optimised and Functionally Integrated Shotcrete 3D Printing Elements for Multi-Storey Structures",
  doi               = "10.3390/buildings15091461",
  year              = "2025",
  journal           = "Buildings",
  volume            = "15",
  number            = "9",
  pages             = "1461",
}

Formatted Citation

IEEE

R. Dörrie, “From Digital to Real: Optimised and Functionally Integrated Shotcrete 3D Printing Elements for Multi-Storey Structures”, Buildings, vol. 15, no. 9, p. 1461, 2025, doi: 10.3390/buildings15091461.

CMOS

Dörrie, Robin, Stefan Gantner, Fatemeh Salehi Amiri, Lukas Lachmayer, Martin David, Tom Niklas Rothe, Niklas Freund, et al.. “From Digital to Real: Optimised and Functionally Integrated Shotcrete 3D Printing Elements for Multi-Storey Structures”. Buildings 15, no. 9 (2025): 1461. https://doi.org/10.3390/buildings15091461.