Design and Fabrication of Formwork for Shell Structures

Based on 3D-printing Technology

Xiao Zhang1 , Chao Yuan2 , Liu Yang3 , Peiran Yu4 , Yiwen Ma5 ,
Song Qiu6 , Zhe Guo7 , Philip F. Yuan8
1,2,3,4,5,6
Tsinghua University 7 Hefei University of Technology 8 Tongji University
1,2,3
{z-x20|yuanc19|yl-19}@mails.tsinghua.edu.cn 4 [email protected]
5
[email protected] 6 [email protected] 7 [email protected]
8
philipyuan007}@tongji.edu.cn

Shell structure is a kind of structure using a small amount of materials to obtain a

large-span multi-functional space. However, lots of formwork and scaffold
materials are often wasted in the construction process. This paper focuses on the
shell structure construction using robotic 3D printing PLA (an environmental
friendly material) technology as the background. The author explores the
possibility of 3D printing technology in shell construction from small scale
models in different construction method, and gradually optimizes the shell
template shape suitable for PLA material in full-scale construction. Finally, the
research team chose the bending-active 3D printing type and completed the
construction of three full-scale concrete shell molds. Under the guidance of
professor Philippe Block, the research team finished the final 3D printing mold
with optimized slicing and bending logic and successfully used it as the template
mold to carry the tiles which proved the feasibility of this construction method.

Keywords: Shell structure , Formwork , Geometric analysis, Form-finding, 3d

printing

1. BACKGROUND method wastes scaffolding materials and requires a

Shell structure is a good choice to cover large spans lot of time during the construction process. At the
with less material, its light architectural form also same time, in order to carry out the construction ac-
conforms to the aesthetics of structural mechan- tivities in a more environmentally friendly way, this
ics(Méndez Echenagucia et al., 2018). The manu- paper focuses on the shell structure construction us-
facturing process of the shell first requires physical ing 3D printing PLA technology as the background.
form-finding, and then the geometry form will be PLA is a kind of printing material which can be made
fitted by the template in the process of construc- by recycling plastic.
tion, the shell is finally finished by concrete ,brick
or wood. And then the scaffolding and template
are removed. However, this traditional form-finding

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 1.2 Material Efficiency Optimization Figure 1
Searching Left: 3d printed
Material efficiency is becoming a critical design driver unreinforced,
in the construction industry. When the flexible ma- structural floor
terial is used as a formwork, it needs to bear a cer- (Philippe Block et
tain load without deformation, so it is necessary to al., 2016), Right:
structurally strengthen itself. How to apply proper 3D-printed
1.1 3D Printing Formwork Techniques amount of material in necessary part and also waste formwork for
Searching less material to decrease formwork self-weight is also UHPFRC material (
In recent years, with the efforts of Block Research very important. Traditional shell Material Efficiency Andrei Jipa et al.,
Group in ETH, the shell construction method through Optimization methods can be divided into three cat- 2016)
3D printing technology has gradually matured. Their egories:
researches can be roughly divided into two direc-
tions: the first direction is direct printing of build- • Size Optimization (Mijar et al. 1998). There are a
ing materials (Philippe Block et al., 2016). Although number of different topology optimization algo-
the formwork is omitted in this construction process, rithms, including Solid Isotropic Microstructure
the high price of the equipment and the limitation of with Penalization (SIMP), Evolutionary Structural
the processing size (4 * 2 * 1meters) at the present Optimization (ESO). Researches found the shape
stage result in that it can only be used for the con- optimized are often complex and some morpho-
struction of the floor level (Fig 1. Left). The second logical transitions exceed the set limit (less than
type is 3d printing shell structure formwork (Andrei 45°deflection in Z direction) of the FDM 3d print-
Jipa et al., 2016). This construction method is delicate ing.
and can form a beautiful texture on the concrete shell • Enhancement at the section on shell geome-
surface, but the construction process itself does not try structural lines. Taking the Roman Gymna-
make full use of material properties of the mold itself, sium as an example, it is converted into a spa-
and printing the template layer by layer will consume tial structure by setting the beam to the geo-
a lot of time (Fig 1. right). Therefore, the first aim of metric line position of the shell. However, this
this paper is to 3d print the shell mold by the way of reinforcement method is not based on finite el-
robotic 3d printing, and make full use of the mate- ement analysis which means not every part of
rial properties of the mold itself in the process of shell the material is useful and it is more like a global
structure construction. strengthen strategy.
• Enhancement of the principle structural stress
lines of the shell structure. This analysis requires Figure 2
a combination of finite element analysis to sim- Left: Enhancement
ulate the transfer of force flow through com- at the section on
puter simulations and to strengthen the cas- shell principle stress
ing at these locations(Adriaenssens et al., 2014). lines in Gatti Wool
This reinforcement technique is also related to Mill (Pier Luigi Nervi
topology optimization and is suitable for Irregu- ,1951), Right:
larly shaped shell reinforcement(Tam, 2015). Re- principle stress lines
searchers used Millipede plug-in with Rhino and found by
found the principle stress lines according to the researchers with
load and support situation of Gatti Wool Mill de- Millipede plug-in.
signed by Pier Luigi Nervi in 1951. Through this

488 | eCAADe 39 - Performance based design - Volume 1

 experiment, the research team found it useful have the mechanical properties of resisting deforma-
for principle stress lines enhancement on shell tion, the research team used a 3d voronoi polygon
structure by planner construction (Fig.2). to fill the shell first, and then increased the density
of the helmet at some part based on the collision
experiment, and completed the global 3d printing.
2. INTRODUCTION However, it is impossible for this global 3d printing
This paper presents the research, design , structural method to move to the architectural scale, because
performance simulation and construction of a full there is no such huge printing equipment. Therefore,
scale thin 3d printed bending-active formwork for the research team tried to use discrete and expanded
shell structures (Fig.3). In the small-scale model, the methods to construct the shell template. In the sec-
research team carried out the research on the unit ond test, the author found that the accumulated er-
type, bending-active type and integrated printing ror of the discrete 3d printing shell formwork units in
type, and used topology optimization method in the the assembly process was large, and finally chose to
test process to minimize the use of 3D printing ma- use the expanded 3d printing formwork construction
terials. In this paper, author will discuss the possibil- method.
ity of 3d printing shell and topology optimization de- In the process of applying the deployable 3d
sign of shell structure from small scale model. Finally, printing formwork to the construction of large-scale
through three full-scale printing experiments, author pavilion, the research team conducted three experi-
will present the 1:1 prototype construction optimiza- ments on the printing method and slicing logic. The
tion process, and summarize the design method of first 3D printing mold can’t bear the concrete due
3d printing bending-active shell formwork. to the surface texture during the printing process.
The idea of using 3d printing to optimize mate- The second 3D printing mold can only carry a small
rial distribution on a shell structure was firstly pro- amount of concrete due to the initial bending logic.
posed by an industrial design research partner. The In the third experiment, the research team optimized
reason for this study is that a helmet design company the element geometry based on the bending-active
hopes the research team to produce a mountaineer- construction method, and finally completed the shell
ing helmet by 3d printing. The first approach the re- mold construction, and successfully built a full-scale
search team tried was global printing. In order to re- brick shell.
duce the self-weight of the helmet and also make it

Figure 3
Work flow

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 3. 3D PRINTING EXPERIMENT OF SHELL tribution is more uniform, which is more conducive
STRUCTURE IN SMALL SCALE to the plane processing. At the same time, it is eas-
3.1 Shell structure design based on volu- ier to be used as a formwork or mold to carry con-
metric modeling method crete or bricks then. But this design method is not
Volumetric modeling is an efficient modeling conducive to be split, integrated printing is more suit-
method. In NURBS modeling, geometries are often able for industrial design, formwork design for archi-
described by parametric curves, while in volumetric tecture scale must consider the split logic.
modeling, points, lines can be transformed into in-
dependent fields, and a certain volume is formed by 3.2 Shell structure design based on unit
wrapping the equipotential surface. The advantage modeling method
of this modeling method lies in the fast operation Through the study of the construction process of a
speed, which can break through the geometric lim- shell structure, the author found that the construc-
itations of the model: the lines in the model are di- tion process is actually a three-dimensional jigsaw
rectly divided into points, and the volumetric model puzzle of the bricks in a certain order. The formwork
is formed by the point cloud. plays the role of supporting the covering like con-
In this paper, the 3D printing shell structure de- crete or bricks, while the scaffold plays the role of
sign of helmet is filled by the 3d voronoi polygon at positioning and supporting. If the unit of the tem-
first, and the curves group on the surface is formed plate itself has the function of positioning, and has a
by the voronoi polygon intersected with the helmet certain compression capacity after the construction,
B-rep. Secondly, the polygon lines group is divided then the use of scaffolding materials can be saved
into uniform point clouds according to the distance. in the process of shell construction. Similarly, the
On this basis, based on the stress diagram provided unit mold is also very conducive to storage and trans-
by the helmet manufacturer according to the impact portation.
test, the author arranged the densified point cloud in According to the geometric structure line of the
the collision concentration area in the helmet geom- shell, the structural lines can be divided equally by
etry. Finally, the author combines the two groups of dislocation. At the same time, the odd and even rows
point clouds and used the “Dendro” plug-in based on of bricks are moved in the normal direction of the
grasshopper platform to turn the points into a closed shell surface to make them staggered. On this ba-
mesh which can be 3d printed(Fig.4). sis, the author makes Boolean operations on the shell
elements to form 102 different bricks, which are 3d
printed. Although the research team has completed Figure 4
the final assembly(Fig.5), but in the process, the re- Volumetric
search team found that the cumulative error is large. modeling design
This may be due to the small size of each block unit for shell structure
and the low printing accuracy, which leads to the based on 3d
shape deformation at the printing turning point of printing technology
each brick. However, if high-precision 3d printing
equipment is used in the construction, the process-
The author found that the point cloud strengthen- ing time of each block will be extended.
ing strategy based on stress analysis is a more effi-
cient formwork design method than shape optimiza-
tion like ESO. Moreover, this method can ensure the
integrity of the shell structure, and the material dis-

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Figure 5 according to the central line symmetry axis and unroll
Up: mold design of it in two parts. On this basis, the author further solved
unit brick of the the principle stress lines of the shell with Millipede in
shell; down: Grasshopper, and then projected it on the developed
assembly and surface. But the problem is that the stress lines gen-
manufacturing erated is random, so it is difficult to generate the 3d
result print path directly with “one stroke”. Generally speak-
ing, the path that should be drawn in one stroke is
regular polygon mesh, so that the vertices of each el-
ement can be sorted, and the path can be generated
by circular algorithm for FDM 3d printing machine.
So the author gets the path which can be printed
continuously by the robotic arm point by point, and
uses the FDM printing method to complete the mold
manufacturing and bending assembly (Fig. 6). The
author bent the printed template to form a double
Through experiments, the author found that the unit curved shell, but also found a problem was found
structure is more suitable for the construction of the that there are still too many work of hand bonding.
shell itself. If we want to use 3d printing materials to So, the author puts forward the idea of unfolding ac-
make shell formwork, we need to reduce the manual cording to the contour of the surface.
splicing part to achieve the accuracy of form finding
Figure 6 process. At the same time, if the customized unit con-
Up: Shell geometry struction method is used to complete the shell unit,
developed based the casting method may be more economical, and 3D
on UV curves; printing is more suitable for the final block mold.
down: final bended
form 3.3 Shell structure design based on
bending-active modeling method
A shell structure is often a hyperboloid like shape,
just like the clothes on the body, but the clothes on
our body can be divided into several pieces of de-
velopable cloth, so that they can be made on a plan
easily. If the shell formwork be constructed in this
way, the fabrication work would be easier. The re-
search team hopes that the double curved shell sur-
face can be fitted into a combination of several de-
velopable surfaces. By unrolling and 3d printing the
single curved formwork piece and bending it, the
built formwork can be fitted into a shape geometri-
cally similar to the hyperboloid shell, and the bended
shape can resist some weight.
3.3.1 Developability optimization by UV curves.
The author splits the double curved shell geometry

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 3.3.2 Developability optimization by profile. Be- 4. 3D PRINTING EXPERIMENT OF SHELL
fore unrolling, it is necessary to extract the long edge STRUCTURE IN FULL SCALE
contour of the shell as the “path”, and make the short 4.1 Pre-bending double layer 3d printing
edge straight as the “section line” to complete the fit- method
ting of the double curved surface, and then unroll the In order to strengthen the bended formwork to
rebuilt single surface through the algorithm (Fig.7). bear certain load, the principle stress lines extracted
For the shell in Figure 7, the author further subdivides by Karamba are printed together with the form-
the shell to make it more similar to the initial shape, work. However, the printed formwork with principle
which is suitable for printing template. In this way, stress lines is very distorted in the bending process.
a single surface can be fitted by the combination of Some areas on the surface would appear unnatural
triangular planes. bending phenomenon, therefore, the bending must
be simulated to make the most reasonable routing
Figure 7
choice. First of all, author simulated the bending of
Unrolled formwork
the plane formwork through abaques, pushing the
according to shell
boundaries of the two ends. However, the simulation
profile
results do not form the preset surface.
Therefore, the research team set the target dis-
placement for each point on the edge, control the
speed and path of each point to simulate the new
bended state. The results show that the distribu-
tion of stress line formwork is very unfavorable to the
bending process. The area where the stress lines in- Figure 8
tersect will form a harder part than surrounding area, Left: 3d printing
which makes it difficult for the formwork to bend, and shell path; right:
even if the edge is locked on the target contour, the plane printed shell
whole formwork is still not compliant (Fig.9). formwork and
space bended
geometry
On this basis, the author projects the principle stress Figure 9
lines onto the planar formwork. As shown in Figure Up: Bending test of
8, the upper layer is the principle stress line layer, and shell formwork by
the first layer is the base. The one stroke path of the Abaqus; down:
base is easy to generate, but there are many singu- uneven distribution
lar points in the principle stress line path, which can of internal
only be edited manually. The author 3d printed the members of
formwork and bent it into shape (Fig. 8). This pro- formwork
cess requires very little manual bonding process, has
a high degree of mechanization, and the shell formed
by bending has a certain bearing capacity, so the au-
thor decided to deepen the large model production.

492 | eCAADe 39 - Performance based design - Volume 1

 In order to find the most suitable uniform mesh for allel grid, which is not suitable for plane printing in
bending, the author decided to use three kinds of bending simulation, but can increase the integrity of
line distribution simulation to find the most suitable the datum surface in the secondary printing, so that
shape for bending: 1. Cross lines uniform grid, 2. Hor- it is more stable in the force. 2. Frame strengthening
izontally along the bending direction of the template, line. According to the conclusion of bending simu-
3. The line with constant length in the bending pro- lation, the main stress of the shell is concentrated in
cess. After simulation, we find that the third kind of the edge, so the edge needs to be further strength-
routing can get the closest effect to the target surface ened. 3. Stress line of shell element, the shell element
(Fig.10). Therefore, in the process of full-scale print- is not only subjected to gravity, but also to the pres-
ing, the short line with constant length is printed on sure of the other half of the shell, so the stress line
the bottom layer as the base. of this part of the element is different from the over-
all stress line, and it also needs to be strengthened.
Figure 10 The three groups of lines are printed three times in
With the help of order, and are overlapped and woven to form a self-
bending simulation, supporting shell. However, after the shell mold was
the most favorable made, the author found that its surface texture fluc-
mesh for bending is tuated too much, which was not conducive to the in-
compared and The first task of the research team is to 3d print stallation of concrete gauze. Therefore, this template
selected the base layer, a layer of parallel grid lines on the 3D printing method needs to be improved.
plane with PLA to assist bending, and then 3d print
Figure 11 the stress lines of the whole shell after bending to
Process and surface strengthen shell structure performance. The fab-
texture of full-scale rication of scaffolding needs to first draw the da-
prototype shell tum curve on the plane with the KUKA robotic arm,
and then draw the position of the height position-
ing block at the same time, install the pre-cut height
limit block on the bottom plate, and finally fix the 3d
printed planner formwork on the bottom plate with
tie on the height positioning block. The stress line
material of space printing is modified plastics mixed
with adhesive reinforcement agent. Because of the 4.2 Y-shape block 3d printing method
small contact area of the upper and lower overlap- o show the feasibility of the building technique in a
ping surfaces of the extruded plastics in the second complicated design case of a shell structure, a more
printing, in order to prevent the separation between complex form is designed with the same methodol-
layers, a special path must be used for printing. Af- ogy. In the second printing experiment, the author
ter many experiments, the author needs to raise the has made two improvements: 1. The principle stress
mechanical arm to 5cm above the reference plane for lines on the shell should be evenly distributed, oth-
printing. erwise the bended shape will be greatly affected. 2.
The projection of the first prototype is an isosce- The geometry of the shell itself needs to be more
les right triangle of 2.6 m * 2.6 m, the height of which complex to have universal significance. In the first
is 2.1 m and the thickness of which is 1.5 cm (Fig.11). printing process, there will be many problems in the
In the printing process, there are three kinds of lines: second printing. For example, the extruded mate-
1. The surface structure line perpendicular to the par- rial is very hot, which will lead to uneven thermal ex-

Performance based design - Volume 1 - eCAADe 39 | 493

 pansion and deformation of the shell. At the same a linear system. In the final design of the prototype
time, the author changed segmentation logic. Each tile-vaulted shell with a 7 m * 7 m * 2 m space as well
block starts from the singular point of the shell grid, as a circular tension ring with 6 mm steel as the sup-
extends a distance to each strip direction as the cen- port.
tral block (similar to Y-shape), and then each strip can The shell geometry is mainly a double-curved
be unrolled to make more parts more flexible. surface. In the developable optimization process, the
The intercrossed geometry is then optimized midlines of the surface and the boundary curves are
into a combination of series of lofted developable firstly selected. By moving the midlines a little bit
surfaces. To improve the building process, several higher in the Z-direction, one can change the geom-
side trusses are added to support the structure and etry into some strips lofting the midline curves and
to help for the positioning of the shell surface. With the corresponding curves (Fig. 13).
such guides, the 3d printed formwork can be easily With this geometry, all the surfaces can be de-
assembled to reach the geometry and make it as a fined as developable. As the bending moments con-
pure geometric problem. In the final building pro- centrate mostly on the foot areas of the structure,
cess, 10mm Glass Fibre Reinforced Concrete (GRC) is it makes this part of formwork hard to bend. Un-
casted on-site on the formwork with only supports on der the suggestion of Prof. Dr. Philippe Block, the
the curved edges to test the load-bearing capacity. research team. The contour of the bottom of the
Finally, the 80 kg 3d-printed formwork took the 400 shell is changed into an extended curve to make it
kg dead load successfully. However, the author finds fit the double curved surface better in the bending
that the logic of Y-shaped block leads to the appear- process. But in the bending process, there will still
ance of plane part in the bended shell, and the mid- be a large stress concentration in the middle of the
dle of Y-shaped block can hardly be bent, which does formwork, which will lead to a breaking easily in the
not conform to the characteristics of hyperboloid ge- bending process. The research team decided to re-
ometry (Fig.12). Therefore, the author conducted the duce the material at the stress concentration position
third experiment. of the formwork. After physical experiments, the re-
search team found that the opening in the middle
of the formwork along the folding gap will facilitate Figure 12
the bending process. At the same time, the circular The experiment and
opening contour makes the stress evenly distributed assembly process of
to all positions, which is not easy to cause stress con- y-shape block 3d
centration. The method of finite element simulation printing and casted
(Fig. 14) is beneficial to the further verification of the result by GRC
team’s conjecture. material

Figure 13
Shape optimization
to developable
surface
4.3 Shape optimization for f bending active
3d printing formwork
As the geometric rule in the design process relies on
the Y-shaped surface geometry, it is required in the
early stage of design to define the geometry firstly as

494 | eCAADe 39 - Performance based design - Volume 1

Figure 14 ogy for shell structure. From the helmet to the shell
Shape optimization pavilion in architecture scale, the research team pro-
and FEA analysis for posed a lot of possibilities in different experiments.
better bending Although some of the experiments did not get used
performance in large scale, they may inspire other international
research teams to conduct more in-depth research.
The final pavilion of the process is generated through
a multiphased design-to-fabrication joint workshop
organized by theMIT, ETHZ and Tongji University
where a systematic design method, geometric con-
sideration, structural behavior as well as the bending
simulation are discussed and tested. Furthermore,
software tools such as the Millipede, Karamba, Den-
dro, COMPAS framework, RhinoVAULT, FURobot are
selected to work together in the whole design pro-
cess. Although the research team built the bend-
In the process of research, the results of finite ele- ing active formwork for a brick shell finally, the final
ment analysis are used to interfere with the density global shell structure form is still different from the
of printing template. Finally, the 3d printing path of form found shape in the design process. Whether
the shell formwork is formed by the upper and lower the bending active form can server the mechanical
contours equally divided and connected by disloca- property against gravity should be further studied.
tion. This kind of path planning can be done effi- Part of this paper is revised from some published
ciently without connecting irregular principle stress papers such as the introduction of this methodol-
lines manually. Finally, the research team bent the ogy in the documented book of this workshop (Fab-
3D printing formwork, supported a small amount of Union. ,2019) and a conference paper discussing
stick supporting at the bottom of the formwork, and the design of this tile-vaulted pavilion in IASS2019
covered the upper layer of the formwork with a layer (Yuan, P. F.,&Philippe, B. ,2019). Therefore, the au-
of gauze, so that it can carry bricks. Subsequently, the thors would like to mention again all the participants
research team used a layer of 1cm thick bricks to lay in this ETH/MIT/Tongji joint workshop ‘Robotic Force
staggered joints layer by layer to prevent stress con- Printing’ project.
centration at the joints. After two weeks of incremen-
tal construction, the team completed the construc- ACKNOWLEDGEMENTS
tion of the permanent shell pavilion (Fig 15). Prof. Philippe Block, Prof. Philip F. Yuan, Dr.
Ing. Xiang Wang, Kam-Ming Mark Tam, Gene Ting-
Figure 15 Chun Kao, Zain Karsan, Alex Beaudouin, Ce Li, Ben
Bended 3d print Hoyle, Molly Mason, Weizhe Gao, Weiran Zhu, Zhe
formwork and the Guo, Dalma Foldesi, Hyerin Lee, Jung In Seo, Anna
final permanent Vasileiou, Youyuan Luo, D, Xiao Zhang, Liming Zhang
shell pavilion and Hua Chai.
This research is funded by the National Social Sci-
5. CONCLUSION ence Fund of China (Grant No.17ZDA019)
This paper presents a particular research process of
the design method based on 3d printing technol-

Performance based design - Volume 1 - eCAADe 39 | 495

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