3D Printing Freeform Formwork

The performance of 3D printed formwork and its geometric complexity varies, depending on the type of plastic used for 3D printing the formwork and the printing technology. The three columns showcase the degree of geometric freedom achievable in concrete formwork when printing with different materials—namely PLA, PVA, and PETG—and using different 3D printing techniques—robotic fused granulate fabrication (FGF) and fused filament fabrication (FFF) cartesian machines.

PLA (Polylactic Acid) is a common plastic material in the 3D printing industry, being both biodegradable and produced from renewable, organic starches. PVA (Polyvinyl Acetate) is a water-soluble synthetic polymer often used for support material on complex 3D prints due to its ease of removal when in direct contact with water. This research uses PVA to directly 3D print the formwork parts. Due to its high sensitivity to moisture, PVA requires airtight storage. Because of the material’s sensitivity, PVA can clog the nozzle of a 3d printer. PETG (Polyethylene Terephthalate Glycol) is a thermoplastic copolyester with high chemical resistance, durability, and ductility. It is also fully recyclable.

Acknowledgement for 3D Printing Concrete Formwork Project
Project Instructor: Assistant Professor Dr. Mania Aghaei Meibodi
Contributing Students: Ryan Craney, Han-Yuan Chang, Monik Gada, Feras Nour, Christopher Voltl, Jessica Lin, Chia-Ching Yen, Carl Uwe Eppinger, Aaron Weaver
Funding Support: Master of Science Digital and Material Technologies Program.