3DCP Composite Systems

3DCP Composite Systems: Additive Manufacturing of a Concrete and Cellulose Interlocking Wall was developed within the scope of the INOV.AM (Innovation in Additive Manufacturing) project, namely under WP19 – Rein4Concrete. The project investigates how additive manufacturing can contribute to more sustainable, adaptable, and material-efficient construction systems through the combination of multiple materials, digital fabrication workflows, and assembly-oriented design approaches.

The project proposes a modular wall system composed of uniquely shaped interlocking blocks fabricated through the sequential use of two additive manufacturing processes and materials: concrete and cellulose. Rather than producing monolithic building elements, the proposed approach explores the fabrication of smaller prefabricated components designed for transport, assembly, disassembly, and future adaptability.

The wall system combines a structural concrete layer, responsible for structural performance, weather protection, and geometric interlocking between components, with a cellulose-based interior layer that acts simultaneously as surface finish and acoustic insulation. To support this integration, computational workflows were developed to control block geometry, interlocking logics, fabrication constraints, and acoustic-informed pattern generation for cellulose deposition.

A full-scale prototype wall system was subsequently designed, fabricated, and assembled at the ARENA – Advanced Design & Technology Laboratory of the University of Minho, demonstrating the potential of hybrid additive manufacturing workflows for the development of lightweight, modular, and circular construction systems.

RESEARCH TEAM

João Ribeiro, Tatiana Campos, Filipe Brandão, Bruno Figueiredo, Paulo J. S. Cruz.