Author: DBT

Andrei Jipa, Ana Anton, Lukas Gebhard, Benjamin Dillenburger, 2023

The Nubian Slab is a real-world 3D-printed structural concrete element for a residential building in Zürich. The vaulted slab proposes an innovative material-efficient construction method based on digitally fabricated thin shell stay-in-place concrete formworks. The method targets structural slabs, which contribute up to 60% of concrete consumption in architectural applications. The fabrication process is based on the ancient Nubian vaults. These roof structures feature self-supporting inclined masonry courses that can be built without temporary support. This traditional building technique inspired the proposed layered concrete extrusion process, with the 3D-printed concrete layers being analogous to Nubian brick courses. The key difference to conventional 3D concrete printing is the inclination of the extrusion layers, allowing shallow vaults to be produced suspended in thin air without additional supports. The paper presents the robotic 3D-printing setup with a custom nozzle, the fabrication-informed design considerations, and the current limitations of the process, focusing on the case study of a 16 m2 Nubian slab with an irregular perimeter installed in a residential building. Based on this case study, the paper outlines a comprehensive construction sequence for Nubian slabs, considering discrete prefabricated 3D-printed Nubian formworks, assembly details, reinforcement strategies, functional integration, and in-situ monolithic casting. The proposed 3D-printed Nubian slab system enables innovative material-efficient architectural design solutions that may accelerate construction times on site, facilitate mass customisation, automation and integration, and enhance structural performance while remaining compatible with traditional building practices.

Shuyi Huang, Lucia Licciardello, Ana Anton, 2024

Self-supporting Lamellae is a prototype that demonstrates the potential of 3D Concrete Printing (3DCP) in producing lightweight structural components with high efficiency and minimal manual intervention. Inspired by the branching patterns of mushroom lamellae, the design introduces rib-like folds on the column-slab system. These ribs enhance the structure’s self-supporting capacity during printing and are also structurally informed to integrate the reinforcement system and improve overall performance.

Both the slab and the column can be printed monolithically, eliminating the need for custom formwork, temporary support, tailored substrates, or segmentation. As a result, the system is well-suited to the fast production demands of the construction industry while preserving the benefits of customization and material efficiency enabled by 3DCP technology.

This lamella-based structural system offers a rapid, low-cost, and construction-ready solution for the paradigm of “print structure only” in large-scale 3DCP. It holds potential for prefabricated multi-story buildings, providing an alternative to 3D-printed masonry walls and opening up new design opportunities for automated construction.

Ana Anton, CheWei Lin, 2023

The prototype demonstrates a fabrication strategy for integrating inter-layer reinforcement during the 3D Concrete Printing (3DCP) process, as well as straight reinforcement placed in vertically aligned channels along the outer shell of concrete columns. It represents a significant step forward in the practical application of reinforced 3DCP, with key advancements in material compatibility, design-to-fabrication workflows, and coordinated multi-robot production. An adaptation of this fabrication strategy is employed in the structural system of Tor Alva.

By incorporating features such as thin shells and hollow cross-sections, the system enables material-efficient structural solutions.

This column section embodies a sustainability approach for concrete construction—one that balances performance, minimal material use, and craftsmanship. It highlights the potential of using concrete more responsibly, where each printed component is purposeful, whether in load-bearing capacity, embedded functionality, or aesthetics.

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