Autodesk Research has partnered with Additive Tectonics to develop a new approach to concrete floor construction using 3D printing technology. The collaboration combines 3D-printed formwork, natural fiber reinforcement, and low-carbon geopolymer concrete as alternatives to conventional building methods.
The system addresses three issues with traditional concrete floors: single-use formwork waste, material inefficiency in flat slab designs, and high carbon emissions from cement and steel production. According to the companies, cement accounts for approximately 8% of global CO₂ emissions, while steel contributes another 7-9%.
Additive Tectonics uses Selective Cement Activation (SCA), a particle-bed manufacturing method that binds dry mineral powder in layers. For this project, the companies used econitWood, an upcycled wood-mineral composite, to create permanent formwork with optimized ribbed geometry. The design process utilized Autodesk Inventor Nastran to remove excess material and reinforce areas based on structural load requirements.
The reinforcement system replaces steel rebar with flax fibers, which are robotically placed within the complex formwork geometry using continuous winding paths. A potassium-activated geopolymer mortar serves as the concrete alternative, bonding with the flax fiber reinforcement. The companies report this combination produces a lighter and stronger floor slab compared to conventional methods.
Future development could include embedded building services and attachment points directly in the slab design, potentially eliminating the need for suspended ceilings. Additive Tectonics plans to continue refining the system for deployment in construction projects.
Source: research.autodesk.com