Vacuumatic formwork: a novel granular manufacturing technique for producing topology-optimised structures in concrete

Abstract

Recent developments in computational design, such as structural optimisation algorithms, enable designers and engineers to come up with efficient load-bearing structures in which material is placed where it is mostly needed. This optimisation of the structural topology is often inspired by structures found in nature and can count on great fascination from architects. Well-known builder/engineer Pier Luigi Nervi, for instance, developed and patented in the 1950s a technique for manufacturing structurally highly efficient and aesthetically fascinating ribbed concrete structures. Nowadays, the manufacturability of such topology-optimised structures is considered the bottle neck in the overall building process, despite rapid developments in digital manufacturing techniques in the last decade, such as laser-cutting, CNC-milling and 3D-printing. Although various (traditional) manufacturing techniques are available to produce topology-optimised structures in concrete, such as timber formwork, these methods are typically considered complex, time-consuming, labour-intensive and therefore financially unattractive. A solution might be found in the use of vacuumatically-stabilised granular material as an adaptable mould. The overarching term of this specific technique is referred to as vacuumatic formwork.