3D-printed formwork technology streamlines production reduces material consumption, and enables more complex designs.
Concrete construction has long been a foundation of modern infrastructure, from towering skyscrapers to sprawling bridges. Traditionally, this process relies on wooden or metal formwork—temporary molds that shape concrete as it sets. While effective, these methods have limitations, including high material waste, labour-intensive processes, and restricted design flexibility. These constraints are becoming more pronounced in an industry increasingly focused on sustainability and efficiency.
Enter ETH Zurich’s groundbreaking innovation: 3D-printed formwork. This new technology has the potential to transform the concrete construction industry by streamlining production, reducing material consumption, and enabling more complex designs. The 3D-printed formwork process offers a glimpse into the future of construction, where automation and sustainability take centre stage.
ETH Zurich, one of the world’s leading universities in science and technology, has developed a cutting-edge method for creating formwork using 3D printing technology. The process involves printing formwork from polymer or composite materials with high precision, allowing the formwork to take on much more intricate shapes than those possible with traditional methods.
What sets ETH Zurich’s approach apart is the ability to print formwork directly from digital designs, reducing the need for manual labour and allowing for customization at an unimaginable scale. This shift from manual construction to digital fabrication opens up new opportunities for architectural creativity, faster production times, and more efficient resource use.
One of the most significant advantages of 3D-printed formwork is the reduction in concrete use. Traditional formwork methods often lead to excessive material use, as complex shapes require more concrete to fill the gaps left by imprecise molds. With 3D-printed formwork, however, each mold is designed to fit the exact specifications of the structure, minimizing waste and ensuring that only the necessary amount of concrete is used.
In practical terms, this can lead to significant savings. According to research from ETH Zurich, using 3D-printed formwork can reduce concrete usage by up to 50% in certain projects. Not only does this cut down on material costs, but it also lowers the structure’s overall weight, which can translate to savings in transportation and foundation work.
Beyond the material savings, 3D-printed formwork offers substantial improvements in construction efficiency. Traditional formwork must be assembled by hand, a time-consuming and labour-intensive process that can delay projects and increase costs. In contrast, 3D-printed formwork is produced directly from digital designs, enabling rapid and accurate mold creation without manual intervention.
This automation reduces construction time, as the formwork can be produced and installed more quickly than traditional methods. Additionally, the precision of 3D-printed molds eliminates the need for on-site adjustments, reducing the likelihood of errors and costly rework. Projects can be completed faster, with fewer resources and labour, making the construction process more streamlined and efficient.
The environmental benefits of 3D-printed formwork are substantial. Concrete production is a major source of carbon emissions, accounting for approximately 8% of global CO2 emissions. By reducing the amount of concrete required for construction, 3D-printed formwork can help lower the industry’s carbon footprint. According to ETH Zurich, this reduction in concrete use can decrease CO2 emissions by up to 50% for certain projects, a significant improvement for a sector struggling to minimize its environmental impact.
ETH Zurich’s 3D-printed formwork represents an innovative shift in the construction industry, offering a more efficient, sustainable, and flexible approach to building with concrete. By reducing material use, improving construction speed, and enabling creative architectural designs, this technology can revolutionise how we approach concrete construction. With ongoing advancements and wider adoption, this technology could pave the way for a new era in sustainable architecture, helping to build a more resilient and environmentally conscious future.
