Printed Boat

Large-scale fused deposition modeling (FDM) involves substantially higher material flow rates than conventional additive manufacturing, making thermal effects a critical factor in process stability and print quality. These thermal phenomena impose significant constraints on the design of deposition strategies and the achievable component geometry. To address these challenges, a novel parametric workflow has been developed that enables continuous toolpaths and support-free deposition at overhang angles of up to 45°. The workflow is adaptable to a wide range of large-format additive manufacturing (LFAM) systems, providing a flexible framework for different machine configurations. Its capabilities are demonstrated through the fabrication of a fully functional boat hull featuring a watertight shell and a load-bearing structural design, highlighting the potential of advanced process planning for large-scale additive manufacturing.

Architectural Railings

The geometric freedom offered by fused deposition modeling (FDM) opens up new possibilities for architectural applications, where functional performance and aesthetic quality must be considered simultaneously. Railings represent a particularly demanding example, combining structural requirements with architectural design. A novel computational workflow has been developed that integrates both aspects within a single design process, enabling the creation of visually appealing and structurally efficient railing systems. The generated printing toolpaths are optimized based on numerical structural analyses, ensuring that material is placed where it contributes most effectively to the load-bearing performance. This integrated approach demonstrates how computational design and additive manufacturing can be combined to realize customized architectural components with enhanced functionality and design freedom.

Printed Concrete Formwork

Another promising application of fused deposition modeling (FDM) is the production of formwork for concrete construction, enabling the realization of novel and material-efficient structural designs. In particular, ribbed and waffle slab systems can significantly reduce the amount of concrete required compared to conventional solid slabs, thereby lowering the associated CO₂ emissions. To support this approach, reusable formwork elements are manufactured using FDM, providing a flexible and cost-effective alternative to conventional formwork systems. Initial studies demonstrate that these printed formwork elements can be reused multiple times and are fully recyclable at the end of their service life. This research highlights the potential of additive manufacturing to improve both the sustainability and design freedom of future concrete construction.