Robotic 3D Printing Shapes Modular PETG Tower

Zaha Hadid Architects’ (ZHA) Tech Lab has created a 6-metre-tall 3D-printed model of an air traffic control tower for the ZHAviation exhibition stand at Passenger Terminal Expo 2026 in London. The project demonstrates how robotic 3D printing can produce large architectural components while supporting modular construction and reuse.

Robotic 3D Printing for Architectural Components

The Tech Lab based the installation on an original tower design by ZHA. It designed and manufactured the entire structure in-house with the WASP HDP XL Extruder, a large-format robotic 3D printing system. The tower consists of fifteen modular panels measuring approximately one metre by one metre. The team completed the printing process over 270 continuous hours.

The modular design simplifies transport and installation. The team mounted the printed panels onto a structural metal framework, allowing them to assemble the tower safely inside the exhibition hall. After the event, they can dismantle the installation and reuse it at future exhibitions.

Fire-Resistant PETG Meets Exhibition Requirements

The team selected fire-resistant PETG because it complies with exhibition safety regulations. The material combines strength, dimensional stability and the design freedom of additive manufacturing. These properties make it suitable for large-format printed installations that require both complex geometries and reliable performance.

After printing each panel, the team installed programmable LED lighting inside the structure. The lighting animates the interior surface and highlights the tower’s sculptural form. Together, the printed geometry and integrated lighting create an installation that showcases the possibilities of robotic fabrication.

Multi-Robot Printing Expands Production Capabilities

The project also marked the first large-scale application of the Tech Lab’s second robotic printer. By operating two robots simultaneously, the team increased its production capacity for architectural components.

To support this workflow, ZHA collaborated with WASP to expand the CEREBRO robotic control system. The partners achieved successful multi-robot integration within this production setup for the first time. As a result, the Tech Lab can fabricate larger and more complex architectural elements more efficiently in future projects.

Large-scale robotic 3D printing continues to develop rapidly. Projects such as this illustrate how digital fabrication, modular construction and advanced polymer materials can work together to create reusable architectural installations with greater manufacturing flexibility.

Source: WASP
Photos: WASP / ZHA