3D Printed Formwork for Concrete in Architecture

Field: Architecture, cultural heritage restoration, construction and civil engineering
Technologies Used: Large-format FDM 3D printing (BigRep ONE printer, biodegradable PLA plastic, formwork production for concrete)

About the Project

During the restoration of a heritage building in Kempten, Germany – a former brewery being converted into offices and event space – Geiger Group faced the task of replacing 5 large stone window frames while preserving the building's original aesthetics. Traditional stone carving would have required extremely high time and financial costs, while milling foam formwork was unsuitable due to pattern depth and environmental drawbacks.

Engineering and Manufacturing Solutions

In collaboration with NOWlab@BigRep, an innovative 3D printed formwork solution was implemented:

Large-Format 3D Printing: Using the BigRep ONE printer, formwork elements were printed from biodegradable PLA plastic as monolithic parts based on the provided CAD files.
Precision Concrete Casting: The printed formwork was delivered to a concrete foundry, where precise window frame sections were cast and subsequently assembled directly on-site.
Sustainability and Geometric Freedom: The use of bio-PLA material reduced manufacturing waste, while the digital process enabled the casting of concrete elements with complex geometry and texture.

Results Achieved

50% Lower Costs: Compared to traditional stone carving, the 3D printed formwork solution reduced element production costs by half.
45% Faster Production: The process was shortened compared to resin-coated foam formwork production while maintaining high surface quality.
Personnel Resource Optimization: Architects and engineers were given direct control from the 3D model to the final object on-site.

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Challenge

During the restoration of a heritage building in Kempten, Germany, it was necessary to replace 5 large stone window frames while preserving the building's original aesthetics. Traditional stone carving would have required extremely high time and financial costs, while the alternative of milling foam formwork was unsuitable due to insufficient pattern depth and environmental drawbacks.

Solution

In collaboration with NOWlab@BigRep, a digital manufacturing solution was implemented: using the BigRep ONE printer, monolithic formwork elements were printed from biodegradable PLA plastic based on CAD files. These were then used at a concrete foundry to cast precise window frame sections, which were subsequently assembled on-site.

Result

The use of 3D printed formwork reduced element production costs by half compared to traditional stone carving. The manufacturing process was accelerated by nearly half compared to resin-coated foam formwork production. Bio-PLA material reduced waste and enabled the casting of concrete elements with complex geometry and texture under direct engineering control.