title: A Parametric Form Language for Fibre Reinforced Concrete Prefabricated Façade Elements using 3D Printed Formwork
Creators: name: Quan, Deyan
Publisher: name: University of Liverpool Repository
Year: 2525

description: Digital design tools offer the capability to create intricate geometries, particularly at small scales. However, fabrication challenges frequently arise when attempting to produce these geometries at an architectural scale. Prior investigations into fabrication-driven design methodologies have focused on addressing these challenges by integrating design and fabrication processes. However, there is still a lack of systematic examination regarding the balance between geometric variability and fabrication viability, as well as the integration of fabrication and material constraints in specific design cases. Among investigations of digital fabrication techniques, concrete stands out as one of the most commonly used materials due to its versatility and durability. Prior studies have predominantly focused on concrete 3D printing, often facing limitations resulting from a lack of inter-laminar bonding of the layer-by-layer printing logic. Alternative solutions have been offered by the application of 3D Printed Formwork (3DPF) at various scales; however, such solutions have often encountered shape limitations due to the requirement of including linear reinforcement elements, which limits the full geometric potential achievable through 3D printing technology. Ultra-High- Performance Fibre Reinforced Concrete (UHPFRC), with its use of short and thin fibres as an alternative to traditional reinforcement, demonstrated to provide the potential to push beyond the current geometric boundaries. Nonetheless, its application for façade components design is still predominantly limited to 2D repetitive planar shapes.
To this end, this research extends previous studies in the field of fabrication- driven design by examining and enhancing the interrelations between parametric façade design, fabrication method constraints, and material properties. This research employs UHPFRC with 3DPF, and investigates the design and fabrication of freeform modular façade elements that are geometrically intricate, structurally viable, and efficient in terms of material usage. It develops a parametric façade form language that offers architects a geometry-focused design process that integrates fabrication and structural requirements for designing freeform façade components.
A design-driven approach guides the development of the formwork elements; it is informed by a sequence of parametric design explorations, fabrication feasibility simulations and structural tests. The study adopts an empirical approach, which involves prototype formwork printing for later UHPFRC casting. The cured façade component is then analysed both digitally and physically to ensure its structural viability. The methodology also includes design-related experiments with participants who are digital designers invited to test the overall design workflow.
The contributions of this research span design methodology and fabrication innovations. Firstly, the research extends existing fabrication-driven methods applied to a specific design case. The developed parametric form language acts as a design support tool, guiding architects in form exploration by highlighting fabrication constraints early in the design process. Moreover, the material and fabrication-informed design methodology enables dynamic feedback loops between design, fabrication, and structural simulations. Secondly, this research expands the applicability of UHPFRC façade components and the capabilities of 3DPF for freeform concrete elements. It demonstrates the feasibility of utilising UHPFRC with 3DPF to create geometrically complex elements that fulfil both structural and fabrication requirements. The full-scale prototypes exhibit intricate three-dimensional shapes beyond the scope of traditional formwork, thus challenging the necessity for rebars. These prototypes measure up to 1 meter by 1 meter with a minimal thickness of 25mm and enhance structural performance in addition to addressing concerns of weight and thickness in concrete elements.