In recent years, continuous innovation and progress in 3D printing technologies has led to an increase of applications in the architecture industry. Compared to traditional building molds using wood or steel, 3D printed molds only require inputting the design into 3D printing software to produce the final mold or shape. This is one of the clear advantages of using 3D printed molds for construction because of its efficiency and sustainability.
PolyCore™ ABS-5012, a PolyCore™ pellet, was selected as the material of choice for printing a mold for a custom concrete wall. This cost-effective, 20% glass fiber reinforced ABS compound material is ideal for 3D printed molds and tools used in a low-temperature ranges (ambient up to 80℃). By utilizing this material for mold printing and leveraging the large size and high precision of 3D printing technology, we created a 5m(L)*0.4m(W)*2m(H) branding wall for Polymaker.
This article will reveal the step-by-step process of building this wall with PolyCore™ ABS-5012.
Initially, the designers went beyond the usual design constraints of traditional molds and createed a multi-faceted pattern, incorporating the Polymaker logo, thus utilizing the creative freedoms provided by using 3D printed technology.
For the next steps, the mold designs were printed and processed, taking a total of 16 hours. After printing, the final full-scale form was cut into four parts and the inner surface underwent additional post-processing to ensure a smooth concrete cast finish.
The mold components were then assembled using bolts, while an external support structure was assembled to facilitate a stable concrete pouring process.
Finally, the concrete pouring and demolding stage commenced. This phase involved constructing a reinforcing mesh structure inside the 3D printed form, pouring in C30 concrete, allowing it to air-dry, and then demolding and coloring the structure.
The end result was a branded wall with the Polymaker logo, which then went on to win the TCT Asia Best Application Award - Industrial Product Applications in 2024.
Through innovative research and development, Polymaker continues to enhance the stability and durability of its materials, particularly pellets, for construction applications. This aids in achieving a higher level of design freedom, shorter lead times, reduced production costs, and a lower carbon footprint in the manufacturing process.
It is anticipated that 3D printed buildings will become a key driver in the construction industry's development in the near future, delivering marvelous designs through this new additive manufacturing method, fostering innovation across the board.
