Construction and restoration projects often require large components, customized geometries, and accurate reproduction of architectural details. Conventional mold-making and fabrication methods can become costly and time-consuming when each element is unique or produced in low quantities.

Binder jetting supports the production of façade elements, decorative features, large-format molds, and heritage replicas directly from digital models. Complex surfaces and fine details can be produced without dedicated tooling, making the process suitable for both contemporary architecture and the reconstruction of damaged or missing elements.

Scalable printing platforms allow the same workflow to be used for small prototypes, full-scale architectural parts, and large molds. This creates a more direct route from digital design or scan data to finished construction and restoration components.

Upcycled

Upcycled materials.

Up to 2 meters

Parts up to 2 meters in size.

Complex geometry

Highly complex geometries.

Surface finish

Pleasant surface finish direct from the printer.

High throughput

Minimal labour cost, high throughput.

Application

Gothic reimagined

This architectural panel, designed by Dustin White, designer and researcher at Florida Atlantic University in the USA, demonstrates how digital design concepts can be translated into physical building elements with a high level of detail. Inspired by an AI-generated reinterpretation of Gothic architecture, the project combines contemporary design tools with traditional architectural ornamentation.

The intricate surface textures and decorative features were refined and produced in CONCR3DE limestone. Initial prototypes were manufactured on Armadillo printer, after which the full-scale panels were fabricated on an Elephant printer.

This illustrates how binder jetting can bridge the gap between digital design and architectural production, enabling customized façade elements and decorative features without the constraints of conventional manufacturing workflows.

For larger architectural components, the same binder jetting process can be transferred to the CONCR3DE Elephant platform, enabling full-scale parts to be produced without dividing the design into smaller sections.

Application

NEST floor slabs

These ceiling elements, developed by the Swiss company Stahlton AG, a leading prefab construction component manufacturer based in Switzerland, demonstrate how large-scale binder jetting can support the production of architectural concrete components. Manufactured from GFRC (Glass Fiber Reinforced Concrete), the panels combine structural performance with refined surface detailing for modern building applications.

The molds were produced on CONCR3DE Mammoth, the world's largest binder jet 3D printer. Measuring 5 × 2.5 meters, each mold was fabricated as a single seamless piece using a specialized mortar-based material, ensuring high dimensional accuracy across the entire panel.

By enabling the production of large-format molds without assembly, Mammoth printer supports efficient fabrication of customized architectural elements while maintaining the precision required for demanding construction projects.

Application

Børsen

This statue is a replica of one of the original figures that formed part of the façade of Børsen, the historic stock exchange building in Copenhagen, which was damaged by fire in 2024. Standing 1.5 meters tall, the statue demonstrates how binder jetting can support the reconstruction of architectural and cultural heritage elements.

The replica was produced in a single piece on a CONCR3DE Elephant printer. Despite its size, the print was completed in just 9 hours and manufactured as a hollow structure, reducing both weight and material consumption.

By enabling the rapid production of large architectural elements, binder jetting provides a practical solution for restoration projects where speed, scale, and faithful reproduction are essential.