The Institute of Structural Design and Building Construction (KGBauko) at TU Darmstadt launched a pioneering research and development project that redefines what is possible in 3D Concrete Printing (3DCP). In close collaboration with Sika, the Riedel Bau Group, and Staikos 3D, the team developed a fully 3D‑printed formwork for a topology‑optimized concrete slab spanning 5 × 5 meters — complete with a central mushroom column and an intricately ribbed load-bearing geometry.
Innovative 3D‑Printed Formwork Paves the Way for Smarter Concrete Slabs
The construction industry is undergoing a fundamental transformation. Digital design, automation, and resource‑efficient building methods are reshaping how structures are conceived and realized. To drive this shift forward, an ambitious research and development project was launched at TU Darmstadt’s Institute for Structural Design and Building Construction (KGBauko) in collaboration with several industry leaders.
At the heart of the project lies a fully 3D‑printed concrete formwork designed for a topology‑optimized slab with a span of 5 × 5 meters. Featuring a central mushroom column and a highly efficient ribbed geometry, the structure demonstrates how additive manufacturing can enable forms and load paths that were previously impossible—or economically unfeasible—to build.The innovative formwork acts as a lost formwork system, seamlessly integrating with conventional reinforcement and in‑situ concrete. This hybrid method bridges the gap between cutting‑edge technology and established building standards, creating a structurally sound, code‑compliant, and highly material-efficient component.
Optimized Design. Reduced Material. Maximum Performance.
Through digital simulation and topology optimization, material is applied exactly where structural forces require it—resulting in:
- Significant material savingsHigh load‑bearing performance at minimal self‑weight
- Reduced carbon footprintPrecise, reproducible, and complex geometries
This approach sets new standards for sustainability in structural concrete construction. The project demonstrates the advantages of an integrated, end-to-end digital workflow:
- Topology optimization and structural simulation
- Parametric design of the 3D‑printed formwork
- Additive manufacturing with advanced concrete materials
- Reinforcement, casting, and structural integration on site
This seamless workflow illustrates how digital design methods and automated fabrication can elevate productivity, precision, and construction quality.
From Vision to Reality: The 1:1 demonstrator was produced in an industrial training environment, where the 3D‑printed components were assembled with millimeter accuracy and combined with traditional reinforcement. The resulting monolithic concrete element serves as a real-scale proof of concept for the potential of additive construction technologies.
Extensive tests and analyses accompanied the development process—evaluating load-bearing capacity, deformation behavior, and long-term durability. These insights will help inform future research, industry guidelines, and emerging norms for additive construction methods.
Shaping the Next Generation of Concrete Structures
This project exemplifies a new era in construction: where digital design meets sustainable engineering, where complexity becomes economically viable, and where material efficiency and architectural freedom align. The work underscores the commitment to advancing innovation in the built environment and driving forward the technologies that will define tomorrow’s construction landscape.
