LFAM redefines construction industry, starting with custom column formwork

In construction and architecture, large format 3D printing’s use is rapidly growing. Heron AM has proved to be a powerful solution across applications, including advanced structural parts. Vitruvian, an early adopter of technology, has pioneered the use of LFAM to produce reusable, high-strength formworks for concrete casting.

U.S. regulations on the use of additive manufacturing in architecture and construction structural elements are highly stringent. Recent updates specifically require the integration of load-bearing elements – produced through traditional construction methods – every 6 meters of 3D-printed wall. Vitruvian, an innovative American company leading the field of 3D printed microarchitecture in concrete, has been thinking about how to comply with these regulations without having to rely on traditional methods for the manufacturing of structural columns, a process both time-consuming and expensive.

The traditional process of production for structural columns involves the creation of wood formwork, assembled from numerous milled parts and coated with chemical release agents – particularly polluting and toxic. Once the concrete is poured and cured within the formwork, the entire mold is destroyed to extract the column, resulting in substantial waste of time, money, and materials.

To streamline the process while meeting U.S. regulations, Vitruvian has completely reimagined the process and way of producing load-bearing columns—starting from the very first step: the creation of the formwork. By leveraging Caracol’s Heron AM robotic technology, the company has transformed this traditionally wasteful and rigid phase into a flexible, efficient, and sustainable solution.

From furniture to formwork: unlocking the flexibility of robotic additive manufacturing

Vitruvian, which has already been producing stunning, unique furniture pieces with Heron AM, has pioneered a new frontier in the applications of this technology by applying it to the production of complex, reusable formwork for load-bearing concrete elements. This marks a significant shift unlocking the true versatility of large-scale additive manufacturing in architecture. By rethinking the fabrication process from the ground up – starting with the mold itself – Vitruvian has introduced a solution that drastically improves sustainability, efficiency and design freedom in the construction industry.

Technical Details

• System: Heron 300 + HV extruder
• Nozzle Size: 8 mm
• Material: PP + 30% Glass Fiber
• Size: 600 x 500 x 850 mm
• Weight: 16 kg
• Print Time: 15 hrs

Benefits

• 100% material efficiency – material is deposited only where needed (0% waste)
• 30% reduction in lead times – with fast production times and simplified post-processing
• Full design flexibility – Each component is tailored to the project, overcoming the rigid constraints of traditional carpentry

Advanced materials for a sustainable production process

By adopting advanced materials such as PP, Vitruvian prevents chemical adhesion to concrete, eliminating the need for release agents during the initial casting phases and significantly reducing operational costs and environmental impact.

This material innovation has allowed Vitruvian to manufacture concrete formworks with complete design freedom, ensuring compatibility and seamless integration with other 3D-printed architectural elements within their modular microstructures.

Innovative applications for modular construction

Vitruvian has demonstrated the platform’s versatility and how robotic additive manufacturing can support a wide range of construction applications. This project highlights the adaptability of Heron AM to different design and building needs, enabling more sustainable, modular, and circular construction approaches.

With Caracol’s direct local presence in the United States and a fully Made in USA advanced manufacturing technology, Heron AM is now even more accessible and impactful for the American construction industry.

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