Integrated Fiber Forms

Today’s structural floor systems are labor-intensive to install and constrained to orthogonal shapes, relying on formwork that leads to material waste and elevated carbon emissions. This research introduces a particle-bed 3D-printed, stay-in-place formwork produced from upcycled wood-aggregate. The formwork defines the geometry of the slab, enabling complexity and performance-optimization. Instead of conventional steel reinforcement, robotically wound flax fiber cords are anchored to winding points integrated directly into the printed formwork. Combined with cast geopolymer, this approach eliminates the risk of corrosion and significantly reduces embodied carbon. Because the formwork remains in place, no dismantling or disposal is required, resulting in substantial reductions in labor and construction waste. The system’s topology-optimized geometry improves ceiling-specific acoustic performance, accommodates embedded utility conduits, and can reduce the need for suspended ceilings and thus maximize usable space. The result is a lightweight, trade-friendly floor system that points towards functional and environmental advantages. Its feasibility has been demonstrated at architectural scale through a 1:1, four meter, prototype.