Architects have traditionally been limited by concrete construction techniques that restrict them to casting their designs in flat, angular shapes. 3d concrete printing experts Bruil, in collaboration with 3Dealise and ExOne, however have recently developed an enormous 3d printer and printing method allowing architects total ‘freeform of design’ and the creation of large (1800 x 1000 x 700) and complex 3d printed concrete forms.

To realize these incredible forms, the architect’s model is converted into a mold form and sent directly to the 3d printer. The mold is then printed with a material comprising a mixture of sand and an activator. Once the molds are printed. Concrete can be poured into them. A range of material options including fibre-reinforced formulations are possible before removing the molds. The molds themselves are removed with pressurized water once the concrete has properly cured and set. The molds can also be used for large metal castings.

You can watch a video showing how 3Dealise’s ExOne S-Max Industrial printing system works here.

“This new technology is important for two reasons: First, it enables a world of new possibilities for architects: irregularly curved surfaces, lightweight half-open mesh or honeycomb structures, elements ornamented like 17th century craftwork,” says Roland Stapper, the CEO of 3Dealise. “No longer restrained by technical limitations, the architect’s power of imagination is the new frontier.”

Works completed to date by 3Dealise and Bruil include a twisted H-shape profile, as well as a more sinuous, flowing version. These profiles were recently unveiled at Gevel 2016 and Material Xperience 2016.

Keen to share the expertise and knowledge, Bruil will also be hosting free day-long workshop and seminar in May 2016 entitled ‘Freeform for Architects’ where you can learn about the 3d printing and parametric modelling techniques that are changing the face of the architectural profession.