Developing and testing a novel manufacturing method for complex geometry thin-walled GFRC panels by fabricating a 10 m high, self-supporting GFRC hyperbolic shell

The main bottleneck during the manufacture of complex geometry thin-walled GFRC structures is time taken to make timber or CNC machined moulds for each panel. Complex geometries are comprised many unique panel forms and extensive high costs their often prevents architectural intent from being fully realised. A novel mould-making process proposed that uses a state-of-the-art flexible table with computer-controlled actuators create free-formed geometry, fast-curing, dual-density, polyurethane moulds. This was successfully tested by using sprayed 9 different double curved intermediate 10 m self-supporting, hyperbolic shell, 12 mm thick panels at base structure. completed structure showcased effectiveness reducing production an estimated 100 days days. primary outcome development application new manufacturing method capable casting good surface quality suited more rapid, cost-effective automated large-scale production.