Printing on Wire Frames: A Breakthrough in 3D Concrete Design

Why Print on Wire Frames? Rethinking Reinforcement in Concrete Design

In collaboration with VolkerWessels, we pushed the limits of 3D concrete printing by building directly onto existing wire frame structures.

This method unlocks a new layer of efficiency:

• No formwork required
• Less concrete used
• A tighter bond between structure and design

But it’s not just about saving material — it’s about reimagining how concrete behaves in architecture. Printing on reinforcement gives us control at the surface level, turning raw frames into intelligent, aesthetic forms

Robotic Concrete Printing That Adapts to Complex Mesh Geometry

Working with irregular geometry is where robotic 3D printing shines. The wire mesh served not just as support, but as a canvas.

Using our Standard Printhead, the robotic arm adjusted its path in real time, laying layers of concrete that responded to the underlying mesh.

This kind of frame-adaptive printing introduces a new design logic:

• Geometry isn’t limited by flat planes
• Each layer contributes to structure and visual language
• The print becomes part of the system — not just a skin

Form Meets Function: Aesthetic Expression with Built-In Shielding

This wasn’t just a structural test — it was also about multi-functionality.

The mesh structure, in this case, also served to shield against electromagnetic interference, showing how concrete can become part of a protective system.

At the same time, we embedded custom parametric surface patterns, turning each element into a unique design object with performance built into the form.

Looking Forward: Scalable Potential for On-Structure Printing

This is just a prototype — but the implications go much further.

Imagine:

• Printing directly on rebar cages in architectural façades
• 3D-printed concrete skins on prefabricated structural modules
• Adaptive prints on-site, shaped by real conditions

This method isn’t a side experiment. It’s part of a broader movement in sustainable construction, design automation, and material efficiency — and we’re just getting started.