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

Together with VolkerWessels, Vertico tested 3D concrete printing directly onto existing wire frame structures. The concrete is laid onto the reinforcement itself, so no formwork is needed and less concrete is used. It also creates a tighter bond between structure and design.

Why print on wire frames

Printing on reinforcement changes how concrete behaves in architecture. It gives control at the surface level and turns raw frames into deliberate, designed forms.

The main benefits of the method:

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

Robotic printing that follows the mesh

Irregular geometry is where robotic printing does well. Here the wire mesh acted as both support and canvas.

Using our Standard Printhead, the robotic arm adjusted its path in real time. Each layer of concrete responded to the mesh underneath it.

This frame-adaptive printing brings a different design logic:

• Geometry is not limited to flat planes
• Each layer contributes to both structure and visual language
• The print becomes part of the system instead of a skin on top of it

Form, function and built-in shielding

The test was also about combining functions in one element.

In this case the mesh structure also shields against electromagnetic interference. That shows how printed concrete can become part of a protective system.

At the same time, custom parametric surface patterns were printed into each piece. Every element became a unique design object with performance built into its form.

Scaling up on-structure printing

This is a prototype, but the method points to several applications:

• Printing directly on rebar cages in architectural façades (read how 3D printed façades are changing architecture)
• 3D printed concrete skins on prefabricated structural modules
• Adaptive prints on site, shaped by real conditions

The method is part of a wider effort in sustainable construction, design automation and material efficiency. Read more about how Vertico supports 3D concrete printing in construction.

Credits

• Partner: VolkerWessels
• 3D concrete printing: Vertico