An innovative 3d free-form manufacturing technology for the construction industry
Freeform surfaces play a prominent role in contemporary architecture. However current methods used in the construction industry to produce free-forms involve five major problems. 1. Since they do not involve machine production, the accuracy according to the CAD model is limited and the architect has no direct control on end product. 2. Manually built structures, with two opposing wire mesh frames, with interposed plastic wool often suffer corrosion. This restricts their inclusion in buildings. 3. Due to weight and size of prefabricated free-forms, transportation is difficult and expensive. 4. High manpower demand: at least 3 persons must work on the mounting of each structure. 5. Milling of moulding causes 50% waste. Clever Contour, an Austrian company founded in 2013, is finishing the development of i-Contour, an innovative technology to design and produce large 3D free-forms at 90% lower cost and overcoming key technical barriers such as high weight and transportation difficulties. i-Contour is the first end-to-end manufacture technology for free-forms thanks to two key elements: an own-developed frontend software – a plug-in for Rhinoceros, and an innovative 3D bending machine for plastics. The most relevant Unique Selling Points of i-Contour are: *drastic costs reduction (up to 90%), *real-time control of the overall process, *weight reduction (up to 50%), *easiness of transportation and mounting, and *very fast production time (from weeks down to 2-3 days). The first prototype of the system is already working in our premises and we have successfully executed 6 projects with national and international design studios. We have also engaged several companies from different segments such as concrete manufacturers, formwork producers and architects. By the end of 2023, three years after market launch, we expect to have an accumulated revenue of €21 million and have created up to 20 new positions.