A team of architectural researchers have figured out how to 3D-print concrete structures using a fraction of the material typically used.

The team, led by architecture professor Mania Aghaei Meibodi and researchers Alireza Bayramvand and Yuxin Lin of the University of Michigan's Taubman College of Architecture and Urban Planning, call their technique the "Shell Wall" method. It uses computational design and a robotic-arm print head to create funky-looking shapes that have been precisely calculated to provide structure, or "topology optimization;" the team says the weight reduction in these structures is a staggering 72%, compared to a conventional wall of the same size.

According to the University of Michigan:

"Topology optimization is a technique that generates the most efficient distribution of material based on performance criteria, such as strength or weight, for a given set of support."

"The team created a computational model that synergizes nonplanar and variable material deposition based on the shape and geometric features of the topology-optimized parts. This allows for efficient use of material by placing it precisely where it's needed for structural purposes, 'and eliminates unnecessary overbuilding with excessive amounts of materials,' Aghaei Meibodi said. 'All of these factors combined mean that we can build better, more environmentally friendly structures at a lower cost.'"

Architects are bound to love the expressive shapes that this Shell Wall approach enables. The construction workers overseeing the process, however, will have to get good at bending rebar, which needs to be installed in sections as the printhead makes progress. As you'll see in the example here, it looks like the rebar needs to be more or less precisely shaped:

Here's a longer look at the process:

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