3D-Printed Sand Mould Facades for TU Eindhoven

Design research team

Design, research, and innovation converge in this groundbreaking project with the Technical University of Eindhoven. Collaborating with Prof. Juliette Bekkering, Ass. Prof. Cristina Nan, Alessio Vigorito of Summum Engineering, and Neutelings Riedijk Architects, Vertico explored new frontiers in 3D concrete printing.

The goal

The goal was to investigate the technical feasibility and architectural expression of double-curved façade elements with filigree infill, rethinking prefab construction through robotic printing technologies and circular principles.

Concrete as Lacework: A New Language in Facade Design

What if concrete could flow like fabric?
Using Vertico’s advanced 3D printing system, the team printed delicate, double-curved lattice structures inspired by the visual language often seen in the work of Neutelings Riedijk Architects. With no need for traditional moulds or wasteful materials, these elegant forms emerged directly from a robotically shaped bed of sand - an innovation in both form and fabrication.

This approach enabled complex, lightweight facades and translucent wall elements that would be costly or impossible to achieve through conventional methods.

Toward Circular Construction

A core objective of the research was to propose a method that supports circular construction. By replacing timber, foam, and plastic moulds with reusable sand beds shaped robotically, the project minimized material waste and introduced an environmentally responsible path for producing expressive architectural components.

This methodology not only allows multiple reuse cycles but also opens new avenues for sustainable and material-efficient construction.

Real-World Innovation

The full-scale prototypes printed during the research demonstrate how robotic 3D printing can support both architectural ambition and structural performance. Parametric modeling tools such as Grasshopper were used to define the geometry and print logic, while iterative material strategies helped reduce concrete usage without sacrificing strength or quality.

These facade prototypes can serve as screens, dividers, or structural elements - pointing to a future where concrete printing is not a limitation but a design catalyst.

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