PROJECT INFORMATION
About
3D Concrete Printing
3D concrete printing (3DCP) is an additive manufacturing (AM) process in which objects are built layer by layer in 3D. AM makes formwork unnecessary and is therefore attractive for the construction sector. Due to the high cost of custom formwork, construction engineers and architects were limited in designing efficient concrete buildings and (art) works with complex and optimized shapes and constructions, which could be easily resolved using 3DCP. The application of 3DCP in construction can significantly reduce construction waste from formwork and limit the impact on the environment with less production waste. In addition, additive manufacturing technology’s inherent ability to optimize material use could further reduce the environmental impact of high carbon dioxide (CO2) emissions from cement in concrete. In addition to reducing costs and positive environmental impact, AM can further automate and digitize the sector, and the technology helps transform the construction sector into Industry 4.0. Furthermore, automating concrete production with AM will also help find a solution to reduce physical labour in on-site concrete structures.
DREAMER
Project objective
This project aims to advance 3D Concrete Printing (3DCP) technology from TRL6 to TRL8 by enabling reliable, certified, and scalable production of high-quality concrete structures. Building on Zavhy’s pioneering 3DCP work—including the world’s first 3D printed concrete bridge and the development of fiber-reinforced (FRED) and cable-reinforced (RED) printing technologies—the project addresses two key barriers to societal adoption: achieving first-time-right production under varying conditions and validating printed structures without destructive testing.
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The objective is to develop and integrate a robust digital framework that combines AI-based digital twin technology (AGMAH), predictive modeling (Qugate), and further optimization of Zavhy’s patented 3DCP processes. By linking material properties, reinforcement strategies, and printing parameters to structural performance, the digital model will predict and guarantee quality without full-scale physical testing. This will significantly improve process control, reduce cement use, environmental impact, costs, and failures, while ensuring safety, durability, and certification readiness of 3D printed concrete structures.
