KnitCrete Bridge 2022

2022 Digital Fabrication KnitCrete Research Work

The research project aims to develop a design-informed manufacturing process for complex concrete shell structures in additive manufacturing and thus overcome limitations of traditional construction methods such as formwork- and labor intensity. To achieve this, an effort was made to merge the two technologies of CNC knitted stay-in-place formwork, known as KnitCrete, and robotically applied shotcrete, known as Shotcrete 3D Printing (SC3DP), and thereby reduce their respective limitations. The proposed workflow unites both digital fabrication methods into a seamless process that additionally integrates computational form finding, robotically applied fiber reinforcement, CNC post processing and geometric quality verification to ensure precision and efficiency. As part of a cross-university, research-based teaching format, this concept was implemented in the construction of a full-scale pedestrian bridge, which served as a demonstrator to evaluate the capabilities and limitations of the process. While overcoming some challenges during the process, the successful prove of concept shows a significant leap in digital fabrication of complex concrete geometry, reducing reliance on labor-intensive methods. The results make this fabrication approach a promising starting point for further developments in additive manufacturing in the construction sector.

Publications

Rennen, Philipp; Gantner, Stefan; Dielemans, Gido; Bleker, Lazlo; Christidi, Nikoletta; Dörrie, Robin; Hojjat, Majid; Mai, Inka; Mawas, Karam; Lowke, Dirk; D’Acunto, Pierluigi; Dörfler, Kathrin; Hack, Norman; Popescu, Mariana: “Robotic knitcrete: computational design and fabrication of a pedestrian bridge using robotic shotcrete on a 3D-Knitted formwork.” Frontiers in Built Environment 9, 2023,
doi:10.3389/fbuil.2023.1269000

Credits

Project Team
TU Braunschweig
Institute of Structural Design : N. Hack, P. Rennen, S. Gantner
Institute of Structural Analysis: R. Wüchner
Institute of Building Materials, Concrete Construction and Fire Safety: D. Lowke, I. Mai
TU Munich
Professorship of Structural Design: P. D’Acunto, L. Bleker
Professorship of Digital Fabrication: K. Dörfler, G. Dielemans
Chair of Structural Analysis: K. U. Bletzinger, M. Hojjat
TU Delft
Tailored Materiality Reasearch: M. Popescu, N. Christidi

Student Team
A. Kariouh, C. Zhou, E. Pestriakova, F. Chovghi, F. Wang, H. Liu, J. Sukhowerchov, N. Kovacs, P. Götz, R. Li, R. Pekuss, T. Schlinker, T. Sun, S. Pagés I Diaz, R. San Miguel

Sponsors
DFG (German Research Foundation) TRR277 Additive Manufacturing in Construction, Holcim Innovation Center