Exploration of Incremental Sheet Forming for Application in Formwork Techniques

This research explores the application of Incremental Sheet Forming (ISF) technology in concrete formwork to enhance efficiency and sustainability in construction. Traditional formwork methods suffer from inefficiency and limited customizability, prompting the need for alternatives. In the 1930s, the emergence of pneumatic formwork marked a significant advancement in the construction industry. Subsequently, alternatives such as hanging cable net formwork, CNC milling, and other digital fabrication methods have offered greater flexibility in designing complex geometries. However, challenges persist in scalability and understanding material properties. Despite advancements, the industry still seeks solutions to optimize design and minimize waste in construction formwork techniques. Incremental sheet forming (ISF), a versatile manufacturing technique, enables the rapid production of complex 3D shapes from sheet materials while reducing resource consumption. This research employs a 0.6mm thick aluminum alloy sheet processed with a 6-axis robotic arm, integrating digital design-to-fabrication workflow for precise control. Experiments focus on comparing ISF formwork with other digital fabrication formwork, exploring design control methods, and concluding with concrete casting. Challenges remain in understanding the interaction between concrete properties and the ISF process, especially for large-scale structures. Leveraging ISF in concrete formwork offers the potential to redefine construction practices, balancing design flexibility, sustainability, and customization. This research contributes to advancing construction methods and underscores opportunities for future research in ISF formwork applications.