3D Printing Plastic Molds for Repeatable Casting of Mortarless Topological Interlocking Assemblies

3D printing formwork (3DPF) is a leading method for enhancing the surface quality of precast elements while creating custom complex geometries. Bespoke fabrication methods for 3DPF are incompatible with economic scalability. With increasing awareness of circular economy principles and a growing interest in complex geometric elements, there is a need to explore the design of reusable 3DPF for casting of intricate precast elements. Topological interlocking assemblies (TIA) which are compatible with reversible assembly practices, present an opportunity to design individual blocks with complex curvatures allowing for mortarless assembly. A studio project tasked students with designing TIA blocks and reusable 3DPF for casting them. The project produced installations demonstrating proof-of-concepts for 3DPF for repeated casting of precast blocks. The results bridge the gap between geometric complexity in precast elements and the additively manufactured reusable molds for casting them.