IAB Weimar

A novel approach to additive manufacturing: The vibration-modulated 3D concrete print head

Figure: BFT International

Fig. 1: The process was presented at the IAB-Tage “Beton” in November 2025, among other industry events

Figure: BFT International

Figure: IAB Weimar

Fig. 2: Schematic diagram of the thixotropy- and gravity-based vibration-assisted printing system

Figure: IAB Weimar

Fig. 3: Block diagram of the overall system

Figure: IAB Weimar

Fig. 4: Example of slump on the vibration table and some characteristic curves

Figure: IAB Weimar

Fig. 5: Simulated calibration results for slump flow according to Hägermann (left) and at three different frequencies on the vibration table (right)

Figure: IAB Weimar

Fig. 6: Simulation to determine the nozzle geometry for the discharge process

Figure: IAB Weimar

Fig. 7: Robot and printing system

Figure: IAB Weimar

Fig. 8: Block diagram of the system and user interface of the associated software

Figure: IAB Weimar

Fig. 9: Layer-by-layer deposition and printed specimen with six layers

Figure: IAB Weimar

Fig. 10: Section of three layers on top of each other

Figure: IAB Weimar

Fig. 11: The project was funded by the Federal Ministry for Economic Affairs and Energy. The project was carried out by Euronorm GmbH.

Figure: IAB Weimar

Figure: BFT International

A vibration-modulated printing system developed at IAB Weimar utilizes the thixotropic properties of fresh concrete, eliminating the need for adding a setting accelerator. The gravity-based discharge principle allows for a uniform 3D printing process while expanding the technical options of additive construction. This article discusses the IAB project in detail.

1 Problem definition and possible solution

Driven by innovative technologies and materials, the construction industry is undergoing continuous change. More specifically, 3D printing of concrete will revolutionize the industry because it provides the option of constructing complex buildings and structures directly from printable concrete. However, this process is associated with high demands on the rheological characteristics of concrete. It must remain flowable during conveying and printing and become dimensionally stable (green strength) quickly after discharge without damaging previously...