June 29, 2021


50% material savings for the same structural strength

Hyperion Robotics has been experimenting with post-tensioning  by printing a 5m span beam composed of six 3DCP segments and assembled using 3 steel tension rods.

Using the benefits of 3D printing concrete, we have developed an optimized profile for the beam tuned to resist a uniformly distributed load of up to 4 tons.

“By placing material where it is most needed, and creating catenary shaped conduits for the post-tensioning rods, we have been able to save 50% of material compared to a traditional RC beam of similar bending strength”.

An efficient construction methodology paving the way for large 3D printed structural elements capable of resisting tensile stresses.

This is an exciting experiment demonstrating our ability to shape concrete into an efficient catenary form in order to maintain all of its parts under pure compression against any load cases.

With this approach, we also avoid the need of extra reinforcement and can demonstrate the structural integrity and ductility of the final structure using simple steel connections.

Snapshots of the post-tensioning sequence

Construction Sequence: From printing to assembly

The efficiency of our 3D printer enabled us to print each of the segments in less than 20min. Using simple steel detailing to post-tension the segments and sandwich them between the end plates, we managed to assemble the whole beam in less than 1 hour.

Next step, load testing the beam with 4 tons!

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