WORKSHOP 2   Air Cast Concrete

SU Yunsheng, YANG Hao, FAN Ling
Tongji University

This workshop is based on the New Product Development Fund of Tongji Engineering and Industry Research Institute, which is led by Prof. LOU Yongqi, Future Urban Research Center, senior student team of D&I, with R&D according to Project System, supported by Youth League Start-Up Center, Fablab, and 021 Incubator.

This workshop pushes the current boundaries of design and construction, in which innovations in design processes and material fabrication. Whilst Tongji University is at the forefront in the world in robotic construction, material research, structural calculation, and actual market applications, this workshop picks up the limitations of 3D printing in lower technology means of production. The development trends of the construction industry is to move towards 3D printing entire buildings, and on-site printing.

This project, MINI, is based on a technical patent of Tongji University’s teaching staff and the integrated innovation with collaborations with industry and enterprise. The development of this patent in this workshop foresees the production of a single unit of MINI, to seek the feasibility of this project in low technology means and materials. MINI encapsulates material innovation, architectural parametric design, product and service development and crowdfunding, in one small but ambitious prototype.


Given the capacity to customize a variety of forms of rooms, an air filled film will be automatically shaped and cut, which serves as the formwork for 3D spraying of concrete. This construction system applies gypsum-based printing and reduces the amount of building materials and cost of a conventional room by more than 15%, construction labour and time by more than 50%, while enhancing the user experience and participation.


Students will complete at least one Mini and its interior layout. They will research deeply on material, structure and shape through the manual spraying of the model room. They will also learn about the mechanical arm. The process and research results will be fully recorded as content for further exhibition.

1. Two groups of students make the “Board” and “Skin” with the materials and machines prepared in advance.
2. Moulds made for all the units and models such as the vacuum glass, solar panels and prefab bathroom unit on the “Board”.
3. Combine the “Board” and “Skin ”.
4. Spray Concrete; cure; remove formwork.


Design process uwing Rhinoceros software and plug-ins.

Examples of previous sprayed concrete prototypes

Start Time

9:30 am

Saturday, October 28, 2017

Finish Time

6:30 pm

Sunday, November 5, 2017



Event Participants