DE:Stress Pavilion (2020)
article⁄DE:Stress Pavilion (2020)
abstract⁄PrintCast Concrete investigates concrete 3D printing utilizing robotically fabricated recyclable green sand molds for the fabrication of thin shell architecture. The presented process expedites the production of doubly curved concrete geometries by replacing traditional formwork casting or horizontal corbeling with spatial concrete arching by developing a threedimensional extrusion path for deposition. Creating robust nonzero Gaussian curvature in concrete, this method increases fabrication speed for mass customized elements eliminating twopart mold casting by combining robotic 3D printing and extrusion casting. Through the casting component of this method, concrete 3D prints have greater resolution along the edge condition resulting in tighter assembly tolerances between multiple aggregated components. PrintCast Concrete was developed to produce a fullscale architectural installation commissioned for Exhibit Columbus 2019. The concrete 3D printed compression shell spanned 12 meters in length, 5 meters in width, and 3 meters in height and consisted of 110 bespoke panels ranging in weight of 45 kg to 160 kg per panel. Geometrical constraints were determined by the bounding box of compressed sand mold blanks and tooling parameters of both CNC milling and concrete extrusion. Using this construction method, the project was able to be assembled and disassembled within the timeframe of the temporary outdoor exhibit, produce 1 of waste mortar material in fabrication, and utilize 60 less material to construct than castinplace construction. Using the sand mold to contain geometric edge conditions, the PrintCast technique allows for precise aggregation tolerances. To increase the pavilions resistance to shear forces, interlocking nesting geometries are integrated into each edge condition of the panels with .785 radians of the undercut. Over extruding strategically during the printing process casts the undulating surface with accuracy. When nested together, the edge condition informs both the construction logic of the panel’s placement and orientation for the concrete panelized shell.
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| Year |
2020 |
| Authors |
Battaglia, Christopher; Verian, Kho; Miller, Martin F. |
| Issue |
ACADIA 2020: Distributed Proximities / Volume II: Projects |
| Pages |
202-207 |
| Library link |
N/A |
| Entry filename |
de-stress-pavilion |
