Volumetric intersections: Modularization approaches for freeform prefab concrete construction

The pursuit for more load-adapted, individualized, and at the same time precise building geometries is driving innovation in digital fabrication with concrete towards greater formal freedom and higher degrees of prefabrication. This article reviews the opportunities of using three-dimensional (3D)-printed formwork in the context of pre-fabricated concrete construction. It identifies the geometric specificities future planning tools need to address to incorporate the steps of modularization and fabrication into automatized planning processes from design to production. By reviewing the state-of-the-art fabrication methods for nonstandard concrete geometries, we highlight possible applications and challenges for additive formwork and introduce a volumetric modeling approach to modularize surface and mesh-based 3D design models into solid segments that can form the basis for further formwork planning.