3D Printed Formwork Retained as Finishing Surface
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing formwork systems for constructing linear or flat reinforced concrete elements are labor-intensive, expensive, and inefficient, requiring heavy equipment and tools for placement and removal, and do not inherently provide a visible aesthetic finish or integration of auxiliary facilities like water, electricity, and gas.
Innovation Solution
A method using 3D printing to fabricate formwork elements that remain in place after concrete setting, incorporating hollow spaces for service facilities and made from materials like fibreglass, polypropylene, or composite resins, which also serve as a finishing surface, reducing the need for separate stabilization and bracing elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional pre-fabricated formwork systems are used, then concrete elements can be constructed with structural integrity, but the process becomes labor-intensive and expensive requiring heavy equipment and tools for placement and removal
Solution Approach 1:
The 3D printed formwork serves itself by remaining in place as a permanent finishing surface rather than being removed and reused. The formwork integrates its own finishing function, eliminating the need for separate finishing operations and reducing labor requirements for both construction and demolition phases.
Solution Approach 2:
The invention merges the formwork function with the finishing surface function into a single integrated component. The 3D printed formwork becomes part of the final structure, combining temporary construction support with permanent aesthetic finishing in one element.
2Strength
If traditional formwork systems are used, then concrete elements can be constructed, but additional materials and tooling are required for placing and removing formwork
Solution Approach 1:
The 3D printed formwork serves itself by remaining in place as a permanent finishing surface rather than being removed and reused. The formwork integrates its own finishing function, eliminating the need for separate finishing operations and reducing labor requirements for both construction and demolition phases.
Solution Approach 2:
The formwork performs multiple functions: it provides structural support during concrete pouring, serves as a release agent through its material properties, and becomes the permanent finishing surface. This multi-functionality eliminates the need for separate finishing materials and operations.
3Strength
If reinforced concrete elements are constructed with traditional formwork, then structural requirements are met, but the elements do not inherently provide visible aesthetic finish or integration of auxiliary facilities
Solution Approach 1:
The 3D printed formwork incorporates varying surface qualities in different locations to achieve aesthetic finishes. The printing process allows different regions of the formwork to have different surface textures, patterns, or materials, providing localized aesthetic properties tailored to specific architectural requirements.
Solution Approach 2:
The invention merges the formwork function with the finishing surface function into a single integrated component. The 3D printed formwork becomes part of the final structure, combining temporary construction support with permanent aesthetic finishing in one element.
Solution Approach 3:
The formwork incorporates hollow spaces and channels within its structure that nest auxiliary facilities such as electrical conduits, plumbing, or insulation. These embedded pathways allow services to be integrated directly into the formwork before concrete pouring, eliminating the need for later drilling or attachment operations.
4Strength
If heavy moulds or formwork are used that need to be adjusted and joined with a large number of tools, then concrete elements can be constructed, but the system becomes complex and requires stabilization and bracing elements
Solution Approach 1:
The invention replaces complex mechanical assembly systems with a 3D printing process. Instead of assembling formwork from multiple panels using bolts, braces, and stabilization elements, the formwork is printed as a single integrated structure, eliminating the need for mechanical joining and stabilization systems.
Solution Approach 2:
The invention merges the formwork function with the finishing surface function into a single integrated component. The 3D printed formwork becomes part of the final structure, combining temporary construction support with permanent aesthetic finishing in one element.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces labor and material costs, enhances safety by eliminating the need for heavy equipment handling, and allows for integrated service facilities within the concrete elements, extending the useful life of the formwork and providing a finished aesthetic.
Implementation Method 1
printing, using a 3D printer (19), the mould or formwork (10)
Data Source
Figure 1~3
Figure 4~7
Figure 8~11
AI summary
The invention relates to a method for the production of resilient elements for use in construction. The method comprises the steps of: using a 3D printer to print the mould or formwork (10) of a resilient element, leaving a space (11) to be filled with a resilient material (3), such as cement or concrete; filling the space (11) in the mould with the resilient material; keeping the 3D-printed mould (10) in situ without removing same, such that it serves as the finishing material of the resilient element (13), as part of the facing finish or plasterwork.