Concrete Casting with 3D Printed Formwork

How to Produce 3D Printed Formwork for Concrete Casting 3D printed formwork is a perfect solution for casting complex geometries. The first step is to design and print the formwork. For restoration projects, it is also possible to scan existing elements to create the 3D models for the formwork. If the formwork is larger than BigRep print volume (1m3 on the BigRep ONE, for example) then it can be printed in parts and assembled after. If needed, the 3D printed formwork can be post-processed with a variety of methods. It is also possible to combine traditional formwork for simple shapes with 3D printed formwork for complex parts. Then the concrete is cast using standard methods. Finally the formwork can be cleaned and reused. Concrete formwork in construction can make up 40 - 60% of a total budget, especially for complex shapes such as curved concrete forms. Some designs like organic shapes, double curved surfaces, and cavities are simply not feasible to produce because they require highly skilled laborers to produce customized formwork resulting in high costs, long lead times, and material waste. BigRep 3D printers can produce large-scale, complex formwork up to 3x faster at a fraction of the cost of traditional methods. With BigRep materials, including the new CONCRETE FORMWORK filament, you can unlock the massive benefits of 3D printed formwork. Bespoke Stairs, NEST STEP2-Unit Design by Digital Building Technologies - ETH Zurich with BASF Forward AM & ROK Fabrication System by Digital Building Technologies, ETH Zurich 3D Printed Formwork Solution by BASF Forward AM Precast Concrete by SW Umwelttechnik Structural Design by Walt Galmarini Architecture by ROK Sculpture "Vårbergs Jättar" by Xavier Veilhan and Alexis Bertrand for Stockholm Konst Project Coordination by Atelier Xavier Veilhan / Martin Coevoet Concrete Casting by BB Beton und Bauwaren Additional Molds by Suppelt CNC Installation by Herrljunga Terrazzo Landscape Architecture and Landscaping by Nivå Landskapsarkitektur & Y2 Anläggning Images © Veilhan, Alexis Bertrand / Bildkunst , 2020 and Xavier Vårbergs Jättar