Parametric stay-in-place knitted molds for concrete casting of complex geometries

The global climate crisis challenges designers, engineers and architects to develop new sustainable designs, solutions, and workflows that better use natural resources and reduce the negative impact on the environment.

This research aims to develop a new sustainable solution for the design of building facades constructed from cement-based matrices cast into hybrid knitted molds with self-sensory capabilities.

To answer this goal, the research offers to adopt a multidisciplinary approach that involves advanced materials, digital knitting procedures, and casting techniques. Digital knitting on an industrial double bed V-shaped knitting machine allows the creation of tubular fabrics in a 3D shape. The fabrics will be used to develop smart and hybrid molds for concrete casting, which will enable the creation of complex geometries and reinforced structures to better adhere to environmental demands. The proposed 3D knitted molds will be integrated within the rigid concrete and act as a multi-functional skin and reinforcement for the tiles. We intend to develop a workflow for designing and manufacturing the knitted molds for the tiles, developing designated concrete compounds, and establishing a method for manufacturing the concrete tiles. Furthermore, integrating the tiles with the built environment demands continuous monitoring of its functional performance. By using electrically conductive yarns as a skeleton of the knitted molds, a smart self-sensory tile with integrated monitoring capabilities will be gained.

The research outcomes will consist of a workflow, manufacturing methods, and technologies for producing hybrid tiles.

Collaboration:

The project is performed in collaboration with Mr. Yoav Shterman and prof. Yiska Goldfeld