Fluid Forms

Technical innovation lies at the heart of Fluid Forms. Researchers in ETH Zurich's Digital Building Technologies - a group in the Institute of Technology in Architecture - unveil a new method for 3D printing shells with a three-dimensional quality by using the agile motion of robotic arms to realize non-planar print paths. Standing 2 metres (nearly 7 feet) tall, Fluid Forms explores applications in robotic fabrication. Its lightweight shell fabricated showcases an innovative robotic additive manufacturing method that enables three-dimensional printing of doubly curved thin shells more efficiently.

Innovative 3D print method

The design of Fluid Forms is inspired by the Costa minimal surface, which belongs to a family of shapes that minimize area for a given boundary, resulting in a geometry with remarkable structural properties. This is then materialized with print paths aligned to its principal curvature directions. As a result, the fabrication process has significant advantages compared to planar printing; it reduces the need for sacrificial support and enhances precision and surface quality in high-curvature areas. The print path orientation is controlled through a vector-field optimization method that has been fine-tuned for the specific needs and constraints of non-planar 3D printing. To increase the rigidity of the structure, undulations are introduced that are orthogonal to the print direction. The prototype is put together using a dry-assembly method that facilitates easy disassembly for recycling after the project’s lifetime. This innovative approach opens new horizons for constructing large-scale lightweight structures in architecture with unprecedented precision and material economy.