PLUSH Portfolio

VERTICAL MODULATIONS
ETH Zurich
PROJECT TEAM: ANA ANTON, ANGELA YOO, PATRICK BEDARF,
LEX REITER, TIMOTHY WANGLER, BENJAMIN DILLENBURGER
ETH ZURICH DIGITAL BUILDING TECHNOLOGIES AND PHYSICAL
CHEMISTRY OF BUILDING
DATE BUILT: 2019
Vertical Modulations is an
exploration of the opportunities
and capabilities of concrete
extrusion 3D printing (CE3DP).
This method uses a robotic
arm to extrude concrete onto a
surface in a programmed motion.
The motion is choreographed
by a coding process and can
become as simple or complex
as you would like.
This avenue of concrete
production takes advantage
of the many opportunities
of traditional concrete- it’s
strength, universality, and
malleability. Additionally, it
removes some of the hurdles
that face form-based concrete
construction such as the need
for formwork and the ability to
produce detailed inner cores.
Thanks to these advantages,
CE3DP can produce certain
concrete forms much quicker,
more precisely, and with less
waste than traditional formbased
methods.
To achieve these forms, the
ETH Zurich utilized a code
fully programmed by Python.
This utilized a trigonometric
function engine to establish
a series of point in space
based on their design inputs.
Variables such as wavelength
and amplitude allowed the
team to parametrically alter
the three dimensional form.
The robot would not be able
to move based on a collection
of Cartesian points, instead it
needed a series of path curves.
They utilized a mesh subdivision
engine, transforming the series
of points into one complex and
intricate mesh. To optimize
printability, the team sought
sinous and flowing shapes so
the robotic arm could easily
maintain speed and precision
on its path. A wave motion path
helped achieve this flowing
form- both in 3D and in plan.
With these full scale forms
reaching heights of two meters,
the team quickly identified the
need for internal structure.
Rather than the traditional
material of rebar, this design
needed the robot to also
produce the internal structure.
With the robot being unable
to follow sharp angled paths,
the team developed organic
internal routes that flowed from
the external form, never forcing
the robotic arm to slow down
or move abruptly. Additionally,
the team expererimented with a
variety of print speeds and layer
heights. These changes would
affect the density of concrete per
layer, the cleanliness of each
path, and the density of material.
The most complex design was
printed at 200 m/s with a layer
height of 6 mm. Variables such
as these were able to be tailored
to each of the different team’s
designs-depending on their
scale, complexity, and design
qualities.
Segmented Columns Using Trigonometric Fu
Contrary to traditional 3D printing approaches
the input of a predetermined form which is late
tally sliced, the trigonometric function displace
that are part of the print-path design itself. In th
CE3DP, which has relatively large layer heights
of 4-12 mm, horizontal slicing would predefine
sentation of the design in steps of layers. On the
by varying layer height, vertical geometric cont
design space can be improved. Because the rob
move precisely along a designed curve, the pot
manipulation and expression can be explored. T
coupling of design features with fabrication pa
along a print-path makes this design approach
able for CE3DP.
The experiment in Figure 11 illustrates layer he
tion at constant material flow-rate and variable
(speed of robot movement). It is shown that prin
DSN S 546 Spring 2021 | 131
must be adjusted to local layer height (Figure 1
If print-speed is too high, insufficient material i