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Traditional reinforcement cages are manufactured in a handicraft manner and do not use the full potential of the material, nor can they map from optimised geometries. The shown research is focused on robotically-manufactured, structurally-optimised reinforcement structures which are prefabricated and can be encased by concrete through SC3DP in a combined process. Based on the reinforcement concept of "reinforcement supports concrete," the prefabricated cages support the concrete during application in a combined AM process. To demonstrate the huge potential of combined AM processes based on the SC3DP and WAAM techniques (for example, the manufacturing of individualized CPS), the so-called FLOWall is presented here. First, the form-finding process for the FLOWall concept based on fluid dynamic simulation is explained. For this, a three-step strategy is presented, which consists of (i) the 3D modelling of the element, (ii) the force-flow analysis, and (iii) the structural validation in a computational fluid dynamics software. From the finalized design, the printing phase is divided into two steps, one for the WAAM reinforcement and one for the SC3DP wall. The final result provides a good example of efficient integration of two different printing techniques to create a new generation of freeform coastline protection structures. [ABSTRACT FROM AUTHOR]

Traditional reinforcement cages are manufactured in a handicraft manner and do not use the full potential of the material, nor can they map from optimised geometries. The shown research is focused on robotically-manufactured, structurally-optimised reinforcement structures which are prefabricated and can be encased by concrete through SC3DP in a combined process. Based on the reinforcement concept of “reinforcement supports concrete,” the prefabricated cages support the concrete during application in a combined AM process. To demonstrate the huge potential of combined AM processes based on the SC3DP and WAAM techniques (for example, the manufacturing of individualized CPS), the so-called FLOWall is presented here. First, the form-finding process for the FLOWall concept based on fluid dynamic simulation is explained. For this, a three-step strategy is presented, which consists of (i) the 3D modelling of the element, (ii) the force-flow analysis, and (iii) the structural validation in a computational fluid dynamics software. From the finalized design, the printing phase is divided into two steps, one for the WAAM reinforcement and one for the SC3DP wall. The final result provides a good example of efficient integration of two different printing techniques to create a new generation of freeform coastline protection structures.