At Hyperion Systems, we’re pioneering the use of large-format 3D printing to transform how concrete formwork is designed and built—delivering faster, more sustainable, and more cost-effective solutions for modern construction.
Project Overview
In a recent demonstration, Hyperion developed a 3D-printed concrete formwork system designed to highlight the efficiency and flexibility of large-scale additive manufacturing. The goal was to create a durable concrete structure, weighing in at 260 kg, with the entire mould produced in just 10 hours.
The formwork measured 2 m × 2.3 m × 0.3 m and was fabricated using polypropylene reinforced with glass fibre. Hyperion’s gantry system, equipped with a thermoplastic pellet extruder, enabled the continuous production of the mould. The design process combined Rhino3D and Grasshopper modelling to optimise geometry and produce an efficient, project-ready solution.
Why 3D Printed Formwork?
3D printing allows the creation of tailored moulds for concrete casting without the cost and time of traditional formwork methods. What typically requires manual adjustment and lengthy setup can now be achieved in hours, reducing both labour and material demands.
This project demonstrated that large and complex formwork elements can be produced digitally, then fabricated quickly and precisely, supporting faster project delivery and reduced waste compared to conventional approaches.
Benefits for Construction
Rapid Manufacturing: Speeds up the process from design to final mould production.
Sustainability and Efficiency: Reduces material waste by applying material only where needed.
Customisation at Lower Cost: Produces bespoke moulds that meet specific project needs without costly re-tooling.
Enhanced Precision: Delivers consistent and high-quality moulds with advanced digital control.
Digital Integration: Enables seamless workflow from CAD design to physical structure, supporting design flexibility.
Streamlined Process
Design – CAD model of the intended structure.
Mould Creation – Development of a digital model matched to CAD.
Support Design – Internal bracing to manage loads during casting.
Production – Large-format 3D printer creates the mould.
Finishing – Post-processing ensures surface durability.
Looking Ahead
As one of Australia’s early adopters of large-format 3D printing, Hyperion continues to explore how additive manufacturing can reduce costs, streamline project delivery, and enhance sustainability in construction. This demonstration highlights just one pathway where digital design and advanced manufacturing converge to create practical, real-world solutions for the built environment.
Ready to re-think your next project with 3D printed formwork? Get in touch to discuss how our technology can support your construction goals.
