3D-Printed Dual-Banded High Performance Concrete Floor
Authors
Structural and Architectural Design Lead: Dr. Masoud Akbarzadeh
Computational Design: Amir Motavaselian
Additive Manufacturing Design and Optimization: Yefan Zhi
Robotic 3D Printing: Dr. Maximilian Ororbia, Dr. Hua Chai, Noah Callantine, Amir Motavaselian, Yefan Zhi, Andrea Machado Romero, Fang Sun, Dr. Yu Wang, Stephanie Bachir
Architectural Drawings and Documentation: Andrea Machado Romero, Meizhu Xu, Dr. Maximilian Ororbia
Structural Engineering Consultants: Paul Kassabian, Blaise A. Waligun (SGH Boston)
Construction Material: Sika US, Noah Callantine
Facade Cladding: Kuan-Ting (Tim Lai) Lai (RoboticPlus.Tech)
Construction Team: Dr. Masoud Akbarzadeh, Amir Motavaselian, Andrea Machado Romero, Yefan Zhi, Dr. Maximilian Ororbia, Dr. Hua Chai, Fang Sun
Formwork Design: Amir Motavaselian
Formwork Milling: Mahsa Sadat Masalegoo
Construction Support: CL Construction
Construction Coordination: Karl Wellman
Video: Andrea Machado Romero
Animation: Amir Motavaselian
Footage: Andrea Machado Romero, Chase Valdiserri, Yefan Zhi, Fang Sun, Dr. Maximilian Ororbia, Amir Motavaselian, Mahsa Sadat Masalegoo, Yayuan Chi
Project Date
2025
Press Kit
Related Publications
Acknowledgements
This research is funded by the Stuart Weitzman School of Design at the University of Pennsylvania. We are grateful for the support and contribution to the project from the following parties: Frederick Steiner and the Dean’s Office of the Stuart Weitzman School of Design, Christorpher Cataldo, and Amsysco.
Description
The proposed 3D-printed funicular floor system establishes a new structural paradigm that integrates geometry-based efficiency, digital fabrication, and modular dual-banded post-tensioning to substantially reduce material demand and embodied carbon. Conceived as a two-directional, compression-dominant floor, the system comprises five funicular elements assembled into a lightweight concrete structure with minimal reinforcement. Its primary innovation lies in the dual-banded post-tensioning strategy, which enables efficient force transmission in both principal directions while preserving a funicular geometry optimized for axial force flow under combined compressive and tensile actions.
Excluding the foundation, the entire structure is fabricated from 3D-printed concrete using a 5-axis robotic arm. The floor system consists of 24 printed segments and four prefabricated capitals that connect the floor assembly to four supporting columns, each composed of three printed segments. The exterior shell of each column is 3D-printed and serves as lost formwork, enclosing conventional in-situ concrete and reinforcement to meet structural, durability, and code requirements. Collectively, the printed components form a highly integrated structural and architectural system supported by four columns.
Quantitative comparisons further demonstrate the advantages of the proposed system over conventional construction methods. Relative to a typical post-tensioned slab approximately 9 inches thick, the system achieves a 40% reduction in concrete volume, increases available surface area for potential carbonation by at least 65%, and reduces post-tensioning reinforcement by 81%, based on the PTI Manual. Compared to a conventional reinforced concrete slab approximately 14 inches thick, the system reduces concrete volume by 57%, increases surface area by at least 62%, and decreases steel reinforcement by 94%, in accordance with ACI 318.
