Creating very large scale constructive elements through 3D printing

CONCR3DE has made significant strides in the construction industry with its groundbreaking 3D printing technology. Our team has developed and patented a method that enables the large-scale production of parts using binder jetting technologies. This innovative approach has the potential to transform traditional manufacturing processes and open up new possibilities for complex and efficient construction projects.

Key advantages of the CONCR3DE production technology include:

• Economical: Binder jetting offers a cost-effective solution for producing very large-scale parts, reducing the need for traditional manufacturing methods.
• Complex shapes: CONCR3DE enables the creation of intricate and complex shapes that would be difficult or impossible to achieve using conventional techniques.
• High precision: 3D printing offers exceptional precision and accuracy, enabling the industrial production of t parts with tight tolerances and big dimensions.

Our technology has immense potential for the construction industry, combining the efficiency of non-standard industrial manufacturing with the design and engineering capabilities of new digital design tools.
This technology has already been put to the test in real-world projects. Stahlton Bauteile AG, a partner in the NEST project, utilized our 3D printing technology to fabricate large-scale molds measuring up to 6 x 3 x 1 meters. These molds were used to create unique floor slabs for the STEP2 unit of the Empa building, demonstrating the ability to produce complex and high-precision components. CONCR3DE developed with the partner the 3D printer and the molds technology for manufacturing ribbed filigree slabs that can span up to 14 meters while minimizing material usage, offering a promising solution for efficient and sustainable construction.

The primary advantage of this technology is its ability to fabricate extremely complex molds with exceptional precision. These molds could be produced economically and with a tolerance of 0.3 mm over a length of 6 meters. The level of detail achieved is remarkably high, as clearly demonstrated in the image below.

Stahlton Bauteile utilized the 3D-printed formwork to create precast elements with integrated beams that are pre-stressed in two directions. This prestressing significantly enhances design flexibility and increases the possible span of the elements, expanding their potential applications. Functional components are already incorporated into the elements during manufacturing. On-site, the precast elements, equipped with shear and connection reinforcement, are lifted into place by a crane. Mesh reinforcement is then added for the top layer, followed by the pouring of in-situ concrete. This process results in a monolithic reinforced concrete slab with integrated beams that are strategically thinned in certain areas to optimize material use. The prefabricated slab elements serve as temporary formwork, ensuring a defined surface finish. To optimize the room acoustics, innovative acoustics boxes are integrated into the slab. The interior of the box consists of a mineral clay foam created by BASF, which has better sound absorption in the mid-frequency range than conventional sound absorbers.

During this project CONCR3DE partnered with leading companies in the construction industry, including directly with Stahlton Bauteile, and indirectly with BASF, ROK Architekten, and WaltGalmarini. These collaborations have been instrumental in developing innovative applications for innovative technology and ensuring its successful implementation in real-world projects.

Our 3D printing technology represents a significant breakthrough in the construction industry that extends well beyond renovation and decorative elements alone - and well into the constructive realm. By enabling the large-scale production of complex and high-precision parts, our binder jetting technology has the potential to revolutionize manufacturing processes and drive innovation in construction projects. As CONCR3DE continues to develop and refine its technology, we can expect to see even more exciting applications and advancements in the years to come.