Fabio Scotto

Last Name

Scotto

First Name

Fabio

ORCID

0000-0002-0501-6576

Organisational unit

09892 - Mitterberger, Daniela / Mitterberger, Daniela

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Publications 1 - 6 of 6

Eggshell: Ultra-Thin Three-Dimensional Printed Formwork for Concrete Structures
Burger, Joris Jan; Lloret-Fritschi, Ena; Scotto, Fabio; et al. (2020)
3D Printing and Additive Manufacturing
vConcrete is a material favored by architects and builders alike due to its high structural strength and its ability to take almost any form. However, to shape concrete structures, heavy-duty formwork is usually necessary to support the fresh concrete while curing. To expand geometrical freedom, three-dimensional (3D) printed concrete formwork has emerged as a ﬁeld of research. This article presents one possible application, a novel fabrication process that combines large-scale robotic fused deposition modeling 3D printing with simultaneous casting of a fast-hardening, set-on-demand concrete. This fabrication process, known as ‘‘Eggshell,’’ enables the production of nonstandard concrete structures in a material-efﬁcient process. By casting a fast-hardening concrete in a continuous process, lateral pressure exerted by the fresh concrete is kept to a minimum. In this way, a 1.5-mm-thin thermoplastic shell can be used as a formwork, without any additional support. Geometries of different scales are tested in this article to evaluate the feasibility of the Eggshell fabrication process in an architectural context. An array of printing materials are also tested, and several different reinforcement concepts are analyzed. The ﬁndings are used to produce a full-scale architectural demonstrator project. This article shows that a wide range of concrete geometries can be produced in a material-efﬁcient fabrication process, paving the way toward mass customization and structural optimization within concrete architecture.
Additive Digital Casting: From Lab to Industry
Lloret-Fritschi, Ena; Quadranti, Elia; Scotto, Fabio; et al. (2022)
Materials
Concrete construction harms our environment, making it urgent to develop new methods for building with less materials. Structurally efficient shapes are, however, often expensive to pro- duce, because they require non-standard formworks, thus, standard structures, which use more material than is often needed, remain cheaper. Digital fabrication has the potential to change this paradigm. One method is Digital Casting Systems (DCS), where the hydration of self-compacting concrete is controlled on the fly during production, shortening the required setting time and reduc- ing hydrostatic pressure on the formwork to a minimum. This enables a productivity increase for standard concrete production. More importantly, though, it enables a rethinking of formworks, as the process requires only cheap thin formworks, thus, unlocking the possibility to produce opti- mised structural members with less bulk material and lower environmental cost. While DCS has already proven effective in building structural members, this process faces the challenge of moving into industry. This paper covers the next steps in doing so. First, we present the benchmark and expectations set by the industry. Second, we consider how we comply with these requirements and convert our fast-setting self-compacting mortar mix into a coarser one. Third, we present the next generation of our digital processing system, which moves closer to the industrial requirements in terms of size and the control system. Finally, two prototypes demonstrate how DSC: (a) increases standard bulk production by 50% and (b) can be cast into ultra-thin formworks. We discuss the results and the short-term industrial concerns for efficiency and robustness, which must be ad- dressed for such a system to be fully implemented in industry.
Heritage ++, a Spatial Computing approach to Heritage Conservation
Patankar, Yamini; Tennenini, Camilla; Bischof, Rafael; et al. (2024)
RILEM Technical Letters
Historic structures are affected by numerous degradation processes driven by a complex system of interconnected and mutually influencing factors. Preserving these monuments is a multidisciplinary endeavour that extends beyond one-time interventions, necessitating a comprehensive methodology that involves various stakeholders, expert consultations, monitoring tools, and impact assessments. Limitations arise due to communication barriers and difficulty in translating and transferring experience among disciplines, often compromising the collective ability to define the best possible conservation strategies.Recent advancements in 3D modelling and data management technologies offer collaborative platforms for information sharing. However, the complex interfaces of these tools often limit their accessibility, making them exclusive to specialists. Integrating Spatial Computing could address these challenges by fostering intuitive engagement and enhancing accessibility and depth in interdisciplinary interactions. This letter outlines initial efforts in using spatial computing to tackle the challenges of built heritage conservation and presents a vision for its future development.
In-Crease: Less Concrete More Paper
Lloret-Fritschi, Ena; Choma, Joseph; Scotto, Fabio; et al. (2022)
RILEM Technical Letters
Concrete is one of the most used materials after water. Largely owing to this, its environmental impact is substantial, although its embodied carbon per unit volume or mass is low when compared to most alternatives. This, along with the broad availability, good strength, durability and versatility of concrete means that it will remain a material of choice, although more efficient ways of using it must be found. Structurally optimized building components are a means to do this as they can save about 50% material. Unfortunately, however, such elements are presently too expensive to produce owing to them requiring non-standard formwork. It is an objective of digital fabrication to propose solutions to this issue. In this con-text, Digital Casting Systems (DCS) have advanced material control strategies for setting-on-demand in digital concrete processing. Thereby, the formwork pressure is reduced to a minimum, which opens possibilities of rethinking formworks as systems that are dynamically shaping, millimetre thin or weakly supporting the material cast inside. In this paper we present a brief overview of millimetre thin formworks and summarize the first realization of concrete elements that utilizes the mechanics of paper folding to make millimetre thin formworks up to 2.5 meters high. Such formworks could initially be flat packed, erected into shape, and eventually peeled-off and recycled in established material streams. This would reduce waste and transport cost, while offering a surface finish that meets the expectations for exposed concrete surfaces.
Design and Fabrication of a Non-standard, Structural Concrete Column Using Eggshell: Ultra-Thin, 3D Printed Formwork
Burger, Joris Jan; Lloret-Fritschi, Ena; Taha, Nizar; et al. (2020)
RILEM Bookseries ~ Second RILEM International Conference on Concrete and Digital Fabrication
This paper describes the design and fabrication process of a concrete column cast in ultra-thin, 3D printed formwork, using a process known as Eggshell. The column was prefabricated as part of a real-world construction project, serving as the main load-bearing element for a reciprocal timber frame structure. The fabrication of the column required upscaling of the Eggshell process, to allow for the fabrication of elements of an architectural scale. Furthermore, several challenges had to be addressed such as: integration of reinforcement, establishing the formwork design space, and scaling up the 3D printing process. For the production of the final column a 1.5 mm thin formwork was 3D printed, after which it was combined with a prefabricated reinforcement cage and filled with concrete in a set-on-demand casting process. The successful realization of the project provides a first example of a full-scale building element produced with the Eggshell fabrication process. By 3D printing the formwork, geometrical freedom in concrete construction is greatly expanded, as well as formwork waste reduced.
EchoXR: A Collaborative VR Framework for Spatial Acoustics in Architectural Design
Scotto, Fabio; Chao, Chia-Hsuan; Montiani, Giacomo; et al. (2025)
AHFE International ~ Human Interaction and Emerging Technologies (IHIET 2025): Proceedings of the 15th International Conference on Human Interaction and Emerging Technologies (HIET 2025), University of Vienna, Vienna, Austria, August 25-27, 2025.
This paper introduces EchoXR, a multiplayer Virtual Reality (VR) framework enabling real-time, collaborative exploration of architectural acoustics. By leveraging advanced tracking and spatial audio technologies, participants can co-experience how design changes—such as adding absorptive panels, altering partitions, or varying materials—impact the acoustics of a virtual environment. Although acoustic simulations often require extensive processing time, EchoXR integrates optimized algorithms with VR’s immersive capabilities to deliver a realistic acoustic performance in real time. Notably, users can hear each other’s voices auralized according to the simulated acoustic conditions, providing an immediate, immersive sense of how proposed design modifications affect speech intelligibility and influence overall noise level in the space. .The system supports multiple concurrent users, allowing designers, clients, and stakeholders to engage in synchronous, spatially coherent discussions. Through intuitive 3D user interfaces, participants can collaboratively adjust design elements and instantly perceive the resulting acoustic effects. This shared acoustic experience fosters more informed decision-making, minimizing the need for costly late-stage interventions or hastily added acoustic solutions that can disrupt the overall design concept and function of the space.The preliminary implementation demonstrates the feasibility and potential of collaborative VR auralization for architectural design workflows. By facilitating a deeper understanding of acoustics in the early design phase, EchoXR underlines the transformative role immersive technologies can play in shaping the future of built environments.

Publications 1 - 6 of 6

Fabio Scotto

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