3D printing and incremental forming: new approaches to facade design

3D printing is increasingly establishing itself as a tool for individual and economical solutions in architecture. Researchers at the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) have developed a process that enables the production of complex façade elements without expensive forming tools. A combination of incremental sheet metal forming and digitally controlled printing techniques is used, which offers new possibilities for individual designs and functional coatings.

The process is based on the step-by-step forming of metal sheets with a mechanical spinning mandrel, controlled by a 3D model. This method is particularly economical for medium quantities and one-off productions, as no expensive stamping or deep-drawing tools are required. The Chemnitz research institute has a forming machine that can process steel and aluminum sheets measuring up to four by two meters. The structures created can be formed to a depth of up to 75 centimetres without significantly changing the material properties.

In addition to shaping, the coating plays a decisive role. The use of a form-stable powder coating on the back of the sheet means that the coating remains intact even after mechanical forming. An additionally applied inkjet print enables individual color designs, while a final clear coat ensures UV resistance. This combination of mechanical forming and digital printing technology offers architects and building owners a flexible solution for façades with individual relief structures.

The process not only opens up new scope for design, but also enables the economical production of replacement parts. This technology can provide an alternative, particularly for historical buildings or vehicles for which original forming tools no longer exist. In addition, applications in the artistic field are conceivable, as complex geometries can also be realized. In the long term, its use in façade construction could help to make energy-efficient and creatively sophisticated building concepts easier to implement.