Designing 3D-printed concrete structures with scaled fabrication models

Abstract

This article proposes using scaled fabrication models to assist the design research of 3D-printed discrete concrete structures where full-scale fabrication tests are costly and time-consuming. A scaled fabrication model (SFM) is a scaled model 3D-printed the same way as in actual construction to reflect its fabrication details and acquire alike layer line textures. The components of a 1:10 SFM can be easily produced by consumer-level desktop 3D printers with minimal modification. SFMs assist the design communication and make possible quick tests of distinct fabrication designs that are hard to assess in digital modeling during the conceptual design phase. A case study of a discrete compression-dominant funicular floor derived from graphic statics is presented to illustrate the contribution of SFM to the design research of force-informed toolpathing where the printing direction of a component is aligned to the principal stress line. The design iterations encompass a sequence of component, partial, and full model SFM printing tests to explore and optimize the fabrication schemes where parallel, non-parallel, and creased slicing methods to create toolpaths are compared and chosen to adapt different discrete components.