3D printing aids decorative concrete structure build

UHPC (ultra-high performance concrete) is nothing short of a revolution as far as architecture is concerned. UHPCs are fibre-reinforced concrete types that are six to eight times stronger than conventional concrete, and also much lighter. The significantly denser structure of UHPC also provides excellent material quality and surface finish.

The research activities of EZCT focus on lighter and filigree-like concrete structures that are set to provide a completely new level of design freedom for architects. But for Morel, the immediate need is for a quicker and more cost-effective mould manufacturing process for the UHPC casting. “At this time, the only economic alternative for our research work is to produce the sand moulds using 3D printing," he says.

For a spectacular UHPC exhibit morel was working on – a structure that graced the floor of an architectural trade fair in the FRAC Centre in Orléans last month – he chose the voxeljet 3D printing process to print a total of 130 sand mould halves for the final concrete cast.

After printing, the inside and outside of the various mould halves were treated with epoxy resin and subsequently bonded together. The individual sections were then assembled and bonded to form the complete mould. In order to demonstrate how the complex UHPC structure was created, Morel only partially removed the sand moulds from the structure.

Morel is hopeful that it will eventually be possible to bypass the casting process and the need to 3D print the mould parts altogether, and 3D print any desired UHPC structure directly.

Actually, this has been on voxeljet's agenda for some time now, and the development department has not been idle. The company has been studying techniques for 3D printing concrete materials and hopes that it will one day be able to turn Morel’s vision into reality