2017

The TopOpt Slab is a 2 m² prototype showcasing a highly efficient use of concrete, structurally optimised for minimising deflections. The prototype relied on a hybrid fabrication process combining 3D-printed formworks and ultra-high-performance fibre-reinforced concrete. 

The slab was computationally designed and produced by a multidisciplinary team from PCBM and DBT, two professorships at ETH Zürich with expertise in materials science and digital fabrication. 

The binder-jetted sand formwork was only nine millimetres thick, and it was stabilised with a synthetic surface infiltration agent. The resulting concrete slab weighs circa 120 Kg, only 60 kg/m². With this approach, we demonstrated how 3D printing can be used only minimally, while relying on conventionally cast concrete for the structural performance. We advocate workflows in which expensive digital fabrication is used only where needed. Even if we are only using 3D printing for a small part of the final product, we can still make a significant impact on its performance and behaviour.

Credits:

Design and development

Mathias Bernhard, Andrei Jipa, Dr Mania Aghaei Meibodi, Prof. Dr Benjamin Dillenburger

Materials science

Prof. Dr Robert Flatt, Nicolas Ruffray, Dr Timothy Wangler

Concrete laboratory

Heinz Richner, Andi Reusser

Engineering (Bachelor's thesis)

Felix Stutz, Neil Montague de Taisne,

Assistance

Hyunchul Kwon, Victoria Fard, Nicholas Hoban, Michael Thoma, Philippe Steiner

Partners and sponsors

Christenguss AG, NCCR Digital Fabrication, 

Photography

Andrei Jipa, Hyunchul Kwon, Mathias Bernhard, Philippe Steiner

Funded by the Swiss National Science Foundation (NCCR Digital Fabrication Agreement #51NF40‐141853)