The Diamanti canopy is the outcome of a collaboration between the Polyhedral Structures Laboratory (PSL) at the University of Pennsylvania and several international partners. The 3D printed concrete canopy investigates how digital fabrication, computational design, and hybrid materials can advance structural engineering and architecture.

Combining 3D Printing and Post-Tensioning

The structure combines 3D concrete printing (3DCP) with post-tensioning techniques to create a canopy spanning 10 metres. Unlike traditional concrete structures, which mainly rely on compression, this design uses both compression and tension. Steel cables run through internal channels in the concrete elements. These cables provide the necessary tensile strength, reducing the need for extra reinforcement while ensuring stability under various loads.

The European Cultural Centre’s 2024 biennial exhibition Personal Structures in Venice, Italy, featured the canopy. A cross-laminated timber (CLT) platform supported the structure. The combination of timber and 3D printed concrete offers an alternative hybrid approach for architecture and construction.

Advanced Computational Design

The design team used polyhedral graphic statics (PGS), a computational design method, to shape the canopy. PGS allowed precise control over both the geometry and internal forces. The form is based on a diamond triply periodic minimal surface (TPMS), which strengthens the structure and creates built-in pathways for the tension cables.

The team printed the canopy in nine separate segments. This modular approach made transport, assembly, and post-tensioning easier. The digital fabrication process eliminated the need for formwork, cutting waste and speeding up construction.

Material Development and Testing

Researchers developed a special concrete mix for 3D printing. An accelerated setting system allowed higher print speeds and taller structures. The team tested both small-scale and full-scale prototypes to evaluate the structure’s mechanical performance. Physical load tests confirmed the models’ accuracy.

They also created adaptive slicing and toolpath algorithms. These systems addressed issues like overhangs and geometric complexity, helping minimise material use and printing errors.

Applications for Architecture and Design

The methods tested in the 3D printed concrete canopy can apply to lightweight canopies, pavilions, modular buildings, and other structures. Digital manufacturing, material efficiency, and prefabrication offer benefits for many design disciplines. Combining 3D printing, post-tensioning, and computational design may help reduce material consumption and embodied carbon in future projects.

Source & Photos: Polyhedral Structures Laboratory, University of Pennsylvania