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Research summary report of A07
Wire and Arc Additive Manufacturing (WAAM) of Complex Individualized Steel Components [05.06.2026] Authors Müggenburg, Marc; Doctoral Researcher, marc.mueggenburg@tu-braunschweig.de Hinz, Felix; Doctoral Researcher, felix.hinz@tu-braunschweig.de Unglaub, Julian; Project Leader, j.unglaub@tu-braunschweig.de Institute of Steel Structures, Technische Universität Braunschweig A07 focuses on developing load-specific, individual high-strength low-alloy steel DED-Arc components, understanding strengthening solutions for existing structures and designing various manufacturing strategies. The specific challenges of adaptive design and adaptive manufacturing of different scale components are addressed and a digital twin including data from the design and manufacturing process, surface geometry and component performance is elaborated. Physical and virtual component tests are carried out to gain comprehensive knowledge on load-carrying capacity, buckling behavior, the effect of imperfections and fatigue life performance. The project …
Research summary report of A10
Earth Additive Manufacturing (EAM) – Material and Process Combinations for AM with Earth-based Materials [13.05.2026] Machner, Alisa; Project Leader, alisa.machner@tum.de Tsiotou, Sofia; Doctoral Researcher, sofia.tsiotou@tum.de Technical University of Munich, TUM School of Engineering and Design, Professorship for Mineral Construction Materials Project A10 aims to design and investigate two novel processes for Earth Additive Manufacturing (EAM), namely, Sprayed Earth Additive Manufacturing (SEAM) as a deposition-based EAM process, and Intrusion Earth Additive Manufacturing (IEAM) as a particle-bed- based EAM process. Alongside the investigations on the two processes, earthen binder mixtures will be evaluated from a material’s perspective regarding the material-process interaction and their variability and suitability for large scale EAM applications. The assessment of both methods and materials will revolve …
Research summary report of C06
Integration of Additive Manufacturing in the Construction Process [07.05.2026] Savadkouhi, Mohammad; Doctoral researcher, m.savadkouhi@tu-braunschweig.de Mawas, Karam; Doctoral researcher, k.mawas@tu-braunschweig.de Maboudi, Mehdi; Associated scientist, m.maboudi@tu-braunschweig.de Gerke, Markus; Project leader, m.gerke@tu-braunschweig.de all: TU Braunschweig, Institute of Geodesy and Photogrammetry (IGP) The main goal of C06/IGP Following a comprehensive study of geometric quality control approaches and stages for integrating additive manufacturing (AM) into construction, the second phase of C06/IGP focuses on integrating AM into a cyber-physical construction system (CPCS). This system enables bidirectional interaction between virtual and physical environments, supporting continuous digital workflows and automated feedback loops. Therefore, the first goal of C06/IGP is to evaluate reality capture sensors in terms of measurement accuracy and level of automation to identify optimal …
Research summary report of A01
Particle-bed 3D-printing by selective cement activation: Sustainability, process enhancement and material models [10.04.2026] Meier, Niklas; researcher, niklas.meier@tu-braunschweig.de Zetzener, Harald; leading researcher, h.zetzener@tu.brauschweig.de Kwade, Arno; project leader, a.kwade@tu-braunschweig.de all: TU Braunschweig, Institute for particle technology The fundamental goal of project A01 is to understand material process interactions in particle-bed 3D printing by Selective Cement Activation (SCA). In SCA, a particle-bed consisting of fine aggregates and cement is applied layerwise. In between the layerwise application, a liquid is applied selectively on the upper layer of the particle-bed. Thereby, the cement hydration reaction is induced locally, and the particle-bed hardens at the selected areas, finally building up to a component. In the second funding period of this project, we focus on …
Research summary report of C04
Integrating Digital Design and Additive Manufacturing through BIM-Based Decision Support and Digital Twin Methods [27.03.2026] Li, Chao; doctoral researcher, chao1.li@tum.de Petzold, Frank; PL, petzold@tum.de Technical University of Munich, TUM School of Engineering and Design, Chair of Architectural Informatics The application of Additive Manufacturing (AM) technology requires careful consideration of AM methods’ boundary conditions. Determining suitable AM methods is critical during the early design stages since changes in design are costly when design becomes more mature. To this end, WP1 of sub-project C04 aims to develop a design decision support system (DDSS) that assists architects and engineers in choosing feasible AM methods for BIM-based design. To achieve this, a knowledge base is formalized, which consists of information on different AM …
Research summary report of A04
Cooperative Additive Manufacturing processes based on Shotcrete 3D Printing [13.03.2026] Rudolph, Jennifer; doctoral researcher, j.rudolph@ibmb.tu-bs.de Böhler, David; doctoral researcher, david.boehler@tum.de Lowke, Dirk; project leader, lowke@tum.de TU Braunschweig, Institute of Building Materials and Concrete Construction and Fire Safety (iBMB) TU Munich, Department of Materials Engineering Project A04 investigates cooperative Additive Manufacturing (AM) processes based on Shotcrete 3D Printing (SC3DP). The aim of this project is to fundamentally understand the SC3DP technology to manufacture sustainable, multi-objective optimised, reinforced concrete components with geometrically precise surface quality and improved building physics by functional integration. Current state of research Current SC3DP systems typically rely on single-nozzle configurations, which limit the process to the application of a single material. To enable …
Researchers at TU Braunschweig develop 3D-printed Spundwand Quartier: Federal Environment Minister presents prototype in Hamburg
Forschende der TU Braunschweig entwickeln in Kooperation mit dem TRR277 AMC ein 3D-gedrucktes Spundwand Quartier: Bundesumweltminister stellt Prototyp in Hamburg vor Februar 2026 – innovatives Umweltprojekt aus der Forschung der Technischen Universität Braunschweig wurde letzte Woche in Hamburg offiziell vorgestellt: Das sogenannte SpundwandQuartier wurde von Bundesumweltminister Carsten Schneider sowie Hamburgs Zweiter Bürgermeisterin Katharina Fegebank präsentiert und bepflanzt. Unterstützt wurde die Entwicklung von der Stiftung Lebensraum Elbe im Rahmen des Projekts „Hamburg – Deine Flussnatur“. Das SpundwandQuartier ist eine innovative, 3D-gedruckte Habitatstruktur, die bestehende Spundwände ökologisch aufwertet, ohne die tragende Infrastruktur maßgeblich zu verändern. Entwickelt wurde der erste Prototyp im Forschungsprojekt „Future Urban Coastlines“ in zusammenarbeit mit dem Teilprojekt Integrated Additive Manufacturing Processes for Reinforced Shotcrete 3D Printing (SC3DP) Elements with …
Research summary report of A02
Particle-Bed 3D Printing by Selective Cement Paste Intrusion (SPI) – Particle Surface Functionalisation, Particle Synthesis and Integration of WAAM Reinforcement [27.02.2026] Freidhofer, Markus; Doctoral researcher; Markus.Freidhofer@iwb.tum.de Riegger, Felix; Head of the research group;Felix.Riegger@iwb.tum.de Technical University of Munich, Institute for Machine Tools and Industrial Management To enable selective paste intrusion (SPI) for practical applications, the inclusion of reinforcement is mandatory. The focus of the first funding period was set on implementing reinforcements in SPI parts by using wire arc additive manufacturing (WAAM). During the first funding period, two main challenges were identified: the need for increased ecological sustainability for the combined process of SPI+WAAM and the need for accelerated process velocities to improve the economic efficiency. Therefore, the …
Research summary report of B05
Principles of Mobile Robotics for Additive Manufacturing in Construction [20.02.2026] David Richter; PhD Researcher, david.richter@tum.de Gido Dielemans; PhD Researcher, gido.dielemans@tum.de Technical University of Munich, Professorship of Digital Fabrication Summary Project B05 investigates additive manufacturing in construction using mobile robotic systems on building sites. By combining the mobility of a robotic base with the dexterity of a manipulator, the project extends fabrication beyond the geometric reach and situational constraints of stationary system. It aims to develop transferable methods with relevance for the in-situ fabrication of large-scale components as well as for future renovation and repair applications. The project focuses on fundamental methods that allow architectural-scale components to be fabricated directly on site, including in confined or existing environments where large gantry …
Research Summary Report of A09
Injection 3D Concrete Printing (I3DCP) – Material Efficient Lightweight Reinforced Concrete Structures Based on Spatially Complex Strut-and-Tie-Models [13.02.2026] Jacobi, Ando; PhD candidate, a.jacobi@tu-berlin.de Technische Universität Berlin, Institut für Bauingenieurwesen Main Goal Injection 3D Concrete Printing (I3DCP) is a new additive manufacturing process where a fluid (material A) is robotically injected into another fluid (material B). The role of material B is to support material A such that material A maintains a stable position. In general, I3DCP can be categorized into sub- categories, whereby the following two subcategories are addressed within this project: Concrete in Suspension (CiS) where concrete is injected into a non-hardening carrier liquid and Concrete in Concrete (CiC) where a concrete is injected into …
Research Summary Report of A07
Wire Arc Additive Manufacturing (WAAM) of High Strength and Individualized Steel Components [30.01.2026] Martin Gabriel Altobelli Research Assistant, martin-gabriel.altobelli@mb.tu-chemnitz.de Kevin Hoefer Research Assistant, kevin.hoefer@mb.tu-chemnitz.de Jonas Hensel Project Leader, jonas.hensel@mb.tu-chemnitz.de Technical University of Chemnitz, Institute Institute of Joining and Assembly Main Goal The objective of A07 is to enable the use of WAAM for large-scale structures and in-situ applications by integrating material behavior and manufacturing limitations into a comprehensive Holistic Design Framework (HDF). The steps in the framework involve the implementation of a “learning-by-printing” …
Research Summary Report of A06
Laser Powder-Bed Fusion (LPBF) of Steel Elements for Construction – Basics of Design and Mechanical Resilience [16.01.2026] Blankenhagen, Jakob; doctoral researcher; Jakob.blankenhagen@tum.de Radlbeck, Christina; project leader; c.radlbeck@tum.de Technical University of Munich, Chair of Metal Structures Suchowerchov, Julia; doctoral researcher; julia.suchowerchov@tum.de Technical University of Munich, Institute for Machine Tools and Industrial Management Summary The project A06 aims to develop a methodology for producing safe and functional structural steel elements for the construction industry using laser …
Research Summary Report of C02
3D Structural Puzzle – Numerical Multi Scale Shape and Topology Optimisation Methods to Additively Manufacture Optimal Structures from Optimised Pieces [19.12.2025] Richter, Christiane; Researcher, christiane.richter@tum.de Prof. Dr. D`Acunto, Pierluigi; Project leader, pierluigi.dacunto@tum.de TUM, Professorship of Structural Design (SD) Main Goal Current building practices often adopt a sequential design approach, where architectural, structural, and fabrication aspects are addressed independently, resulting in excessive material consumption. The CO2 project aims to establish a Holistic Design Framework integrating the above-mentioned aspects. Within this framework, additive manufacturing facilitates structural optimization by enabling the production of bespoke geometries for an effective use of material resources. …
Research Summary Report of B04
Process Control and Adaptive Path Planning for Additive Manufacturing Processes Based on Industrial Robots with an Extended Degree of Freedom [18.12.2025] Heeren, Hauke; Researcher,heeren@match.uni-hannover.de Lachmayer, Lukas; Resarcher, lachmayer@match.uni-hannover.de Prof. Dr. Annika Raatz; Project leader, raatz@match.uni-hannover.de LUH, Institute of Assembly Technology and Robotics Main Goal The research of project B04 is dedicated to extending the current state-of-the-art trajectory planning and process control algorithms for concrete-based additive manufacturing. The objective is to enable reproducible production of multi-material components utilizing mobile robot systems in motion, known as Print-While-Drive. Achieving this requires …
Research Summary Report of A04
Integrated Additive Manufacturing Processes for Reinforced Shotcrete 3D Printing (SC3DP) Elements with Precise Surface Quality [17.12.2025] Dörrie, Robin; Researcher, r.doerrie@tu-braunschweig.de Prof. Dr. Harald Kloft; Project leader, kloft@tu-braunschweig.de Technische Universität Braunschweig; ITE Institute of Structural Design Main Goal The project aims to fundamentally understand the Shotcrete 3D Printing (SC3DP) technology to manufacture sustainable, multi-objective optimised, reinforced concrete components with precise surface quality and improved building physics via functional integration. It seeks to minimise the carbon footprint of 3D printed structures by exploring various material strategies, such as reducing cement content by increasing the aggregate size or replacing cement with a …
Research Summary Report of B04
Process Control and Adaptive Path Planning for Additive Manufacturing Processes Based on Industrial – Robots with an Extended Degree of Freedom [07.11.2025] Akica, Ilknur; Researcher, i.akica@tu-braunschweig.de Hürkamp, André; Project leader, a.huerkamp@tu-braunschweig.de TU Braunschweig, Institute of Machine Tools and Production Technology (IWF) Main Goal The integration of robot-guided additive manufacturing in the construction industry increases the degree of automation and can thus lead to an increased productivity and increased component quality. In shotcrete 3D printing (SC3DP), reproducible manufacturing results and ensuring component quality are major challenges, as the properties of shotcrete depend on many different parameters (e.g. temperature, pressure, water-cement ratio, hardening accelerator). The goal of this …
Research Summary Report of A10
Earth Additive Manufacturing (EAM) – Material and Process Combinations for AM with Earth-based Materials [31.10.2025] Krakovská, Ema; Researcher, ema.krakovska@tum.de Prof. Dr. Kathrin Dörfler; Project leader, doerfler@tum.de Technical University of Munich, Professorship of Digital Fabrication Main Goal The primary research objective of A10 is to conceive and investigate two novel Earth Additive Manufacturing (EAM) processes, their material-process interactions, and their evaluation in large-scale architectural applications. Focusing on the characterisation of earth-based material mixtures (PL Machner), the project investigates a) Sprayed Earth Additive Manufacturing (SEAM) as a deposition-based process (PL Kloft) and b) Intrusion Earth Additive Manufacturing (IEAM) as a particle-bed-based …
Research Summary Report of C09
Environmental Life Cycle Assessment – Determination of Ecological Sustainability Potentials by AMC [07.11.2025] Albrecht, Sophie Viktoria; Researcher, sophie.albrecht@oth-regensburg.de Thiel, Charlotte; Project leader, charlotte.thiel@oth-regensburg.de OTH Regensburg, Construction Materials Main Goal C09 aims to enhance the ecological sustainability of Additive Manufacturing in Construction (AMC) by quantifying and optimizing its environmental benefits through comprehensive Life Cycle Assessments (E-LCA) from cradle to cradle. This involves developing transparent Product Environmental Footprint Category Rules (PEFCR), identifying impactful reduction measures, and integrating circular design strategies to create durable, efficient, and reusable components. C09 enables early-stage, sustainability-focused decision-making, fostering material-efficient, low-impact construction practices and reducing the environmental footprint of the building sector. Summary …
Research Summary Report of C02
3D Structural Puzzle – Numerical Multi Scale Shape and Topology Optimisation Methods to Additively Manufacture Optimal Structures from Optimised Piecest [28.10.2025] Jakobs, Philipp; Researcher, philipp.jakobs@tum.de Wüchner, Roland; Project leader, wuechner@tum.de TUM, Chair of Structural Analysis Main Goal Current building practices often adopt a sequential design approach, where architectural, structural, and fabrication aspects are addressed independently, resulting in excessive material consumption. The CO2 project aims to establish a Holistic Design Framework (HDF) integrating the above-mentioned aspects. Within this framework, additive manufacturing facilitates structural optimization by enabling the production of bespoke geometries for an effective use of material resources. Departing from the conventional sequential approach, the HDF concurrently …
Research Summary Report of A02
Particle-Bed 3D Printing by Selective Cement Paste Intrusion (SPI) – Particle Surface Functionalisation, Particle Synthesis and Integration of WAAM Reinforcement [22.10.2025] Straßer, Alexander; Researcher, alexander.strasser@tum.de Kränkel, Thomas; Researcher thomas.kraenkel@tum.de Gehlen, Christoph; Project leader, gehlen@tum.de TUM, Chair of Materials Science and Testing Main Goal The goal of A02 is to implement reinforcement by Wire and Arc Additive Manufacturing (WAAM) in concrete elements produced by Selective Paste Intrusion (SPI), see Figure 1. The SPI and combined SPI + WAAM process will also be further investigated with a focus on ecological improvements. …
