University of Michigan DART Laboratory unveils free-form 3D printed lightweight concrete Shell Walla

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The DART Laboratory at the University of Michigan has unveiled a new product called Shell Wall, which the organization describes as the first lightweight, free-form 3D printed, structurally reinforced concrete wall. The innovative product leverages DART Laboratory research and development on the use of 3D printing technology to build structures that require less concrete.

Ultra-lightweight 3D printed concrete walls can facilitate the implementation of 3D printing in thermally insulated concrete, requiring less concrete and rebar. Compared to a traditional solid concrete wall of equivalent size, Shell Wall offers a 72% weight reduction while offering the same structural strength. The DART labs technique allows for waste-free concrete construction and efficient use of material by placing it exactly where it is needed for structural purposes.

Shell Walls’ concrete 3D printing method uses a computational model to optimize the layout during robotic construction, reducing the use of concrete and creating greater design flexibility. Shell Wall supports its cargo box with material distributed in a grid of curved ribs. The concrete between the ribs is domed to increase stability and minimize the amount of material.

Shell Wall can also regenerate shapes that closely match the initial optimization taking into account manufacturing and material constraints. For example, during the design phase, it can automatically suggest alternative geometric features in areas where the deposited material could collapse due to a sharp angle or where the robot could collide with itself.

By using commonly available concrete instead of highly specialized mixes, Shell Wall can mitigate challenges faced by the construction industry, including material and labor shortages, rising global greenhouse gas emissions, and new regulations. The product can also help meet the growing demand for homes and infrastructure. Shell Walls’ use of commonly available materials can facilitate the practical implementation of concrete 3D printing for convenient, low-cost housing developments.

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