3D Printing

3D printing has a wide range of applications. From simple parts to complex mechanical components, there are virtually no limits to creativity or geometry. The origins of 3D printing lie in filament-based printing, in which a thin plastic filament is extruded through a heated nozzle. The print head moves across the layers one after another. The gap between the layers determines the resulting layer thickness. It is important that the feed rate and layer thickness are adjusted to the specific print so that the different layers bond and cure sufficiently. In addition to filament printing, there are other processes such as laser welding or laser sintering. These technologies are primarily used in mechanical engineering and the aerospace industry.

In industrial applications, recycling and the incorporation of existing, reused building materials will play an important role in the future. The goal must be not only to print formwork that will later become part of the building, but also to directly create load-bearing and non-load-bearing walls without the need for in-situ concrete for backfilling. Conventional connections and load-bearing elements can then be integrated into the structure. Currently, the use of 3D printing in construction and engineering is still in its early stages. Future projects will demonstrate how the technology can be implemented on a long-term basis and what possibilities exist that are currently still partially or entirely untapped. 

In the case of the server hotel, printing was carried out using a gantry printer from Peri. The advantage of this printing method is its stability and the resulting printing accuracy achieved by minimizing vibrations. Alternative systems that rely solely on single-arm configurations are currently under development and, in some cases, already being tested. However, the choice of building material is critical here, as conventional concrete pumps would negatively affect printing accuracy.

To fully exploit the potential, the surface finish in the server hotel was applied using an automated coating robot. Since the surface texture intentionally reflects the structures created by the 3D printing process, it was decided to leave these surfaces as they are. 

Due to the roughness of the structures, only spray coating is an option. This method now also allows for the use of paints that, due to their vapors, would otherwise require respiratory protection for the workers applying them. Thanks to the robotic application, hours of work in appropriate protective gear are now a thing of the past. However, this places greater demands on the technical expertise of the contractor responsible for the work.

Depending on the material composition, 3D printing offers potential in the areas of sustainability, carbon footprint, predictability, and, above all, visual appeal. According to the manufacturer, the building material from Heidelberg Materials used in the server hotel—called i.tech® 3D—offers the following possibilities:

• Manufacturing prefabricated components directly on the construction site
• 3D extrusion printing of load-bearing and non-load-bearing components
• Printing of straight and curved components

io’s General Planning // plus approach also opens up the possibility of fully integrated planning. Having all specialists from the relevant disciplines available in-house creates entirely new potential. It is therefore conceivable to both digitally plan a factory of the future and optimize it through interfaces so that processes, material usage, energy efficiency, and design go hand in hand. We are excited to see how this technology continues to evolve and what use cases we can identify for your projects.