Concrete Hybridity

Design to Robotic Production of Intertwined Hybrid of Polystyrene and Fibre Reinforced Concrete


Design to Robotic Production Research 2017-18: S. Mostafavi

DIA, M.Arch students: M. S. Moharram, H. Hesham, and M. El-Meligy

TU Delft, MSc studio: C. Du


Studio Tutors and Coordinators, TUD- DIA:  S. Mostafavi, H. H. Bier

Workshop Guest Tutor From TUD at DIA: Y. C. Chiang

Robotic production supports at HS Anhalt: C. Buchmann

Hybrid Assembly Workshop 2017:

DIA: H. Hesham, M. Meligy, M. S. Moharram

TUD: C. Du, F. van Buren, R. Le Roy, T. Nacafi


The Concrete Hybridity is a hybrid system with concrete as structural and EPS polystyrene as the second material. The EPS is acting both as a temporary casting mold as well as a permanent part intertwined with concrete that acts as insulation or finishing. The prototype is extracted from a building skin designed by incorporating structural and environmental analysis that results in a point-cloud. Based on this cloud, stress analysis and the properties of both concrete and EPS, the minimum to maximum dimensions is defined as well as variation in thickness. From the point of view of digital modelling of a hybrid system, this project presents challenges with respect to the translation of voxelated or discretized results of material computation based on topology optimization into a continuous toolpath for multidimensional robotic milling. After casting the outer side of the prototypes are removed with hot wire cutting. Unlike common two-sided mold for casting, this cast consists out of four robotically produced components. Out of these four sub-components, two are closer to the concrete core and remain in place after stripping the formwork. This is due to the three-dimensionality of the concrete structure that interlocks two EPS sub-components together.