Molding Liquid Stone: A Computational and Experimental Mixed‐Method Study of 3D Print Formwork for Interlocking Concrete Modules

Abstract

With bespoke fabrication on one end, and mass production on the other end of the fabrication spectrum, this study investigates custom repetitive manufacturing through molding concrete by using 3D printed formwork. The process demonstrates a proof‐of‐concept for 3D printing elastic resin as a formwork for repeated casting of interlocking concrete blocks. Among the challenges are the method of digitally generating the block geometry and designing the molds to accommodate complex curvatures on four sides of a block while operating within the material limitations of 3D printing with an elastic material. The overall process investigates the limitations of such a system in order to identify future potential for mass customized fabrication employing casting techniques.