Computational Design for Assembly: Automating Design Workflows for 3D Concrete Printed Staircases

Recorded at CDFAM Computational Design Symposium, NYC, October 29-30, 2025https://cdfam.com/nyc-2025/OrganizationScawo3DPresenter:Philip Schneider + Timo ZollnerComputational Design for Assembly: Automating Design Workflows for 3D Concrete Printed Freeform StaircasesPresentation AbstractBuilding large freeform reinforced concrete staircases has always been a challenge. Traditional methods rely on labor-intensive wooden or EPS formwork, making many designs too expensive. This can be changed with Selective Paste Intrusion, a new 3D concrete printing technique by Scawo3D using a large particle bed, with no constraints related to print overhangs or angles.While fabrication now allows full geometric freedom, the design process became the bottleneck. Our previous AutoCAD-based solution, initially developed for producing G-codes for CNC-milling EPS formwork blocks, was not viable for 3D printing. Manual 3D modeling made scaling production impossible, leaving the printer underused. To solve this, Timo Harboe Zollner developed an automated workflow that cuts design time by up to 95%. This approach balances automation with intuitive user input, transforming 2D geometry into finely detailed 3D models in minutes. It integrates SubDs, meshes, volumetric modeling, and implicit modeling, achieving in moments what once took days.This presentation highlights the adaptation of computational design to a new production method—one with only few geometric constraints yet capable of achieving material properties comparable to standard concrete.Speaker BioPhilip Schneider Computational & Architectural Design Lead at Scawo3D and founder of Skeno. He holds a M.A. from TU Munich with a focus on computational methods in architecture and specialises in 3D concrete printing by Selective Paste Intrusion at an architectural scale. Since 2022, he has led the design and fabrication of the first projects realised by SPI in academia and industry.Timo Harboe Zollner is the founder of Timo Harboe ApS, a Copenhagen-based consultancy specializing in automating processes related to geometry, particularly within additive manufacturing. With a background in structural engineering and computational design, Timo collaborates with clients to develop parametric workflows and digital tools that streamline complex design and fabrication processes. His recent projects include automating the generation of 3D-printed formwork for freeform concrete staircases together with Scawo3DAbout CDFAM:CDFAM is a global symposium series at the forefront of computational design, advanced manufacturing, and performance-driven engineering. With a strong emphasis on innovation, CDFAM highlights how leading companies and researchers are leveraging AI, machine learning, and simulation technologies to drive the next generation of design tools, workflows, and digital fabrication methods.The symposium fosters cross-disciplinary collaboration and knowledge exchange between designers, engineers, and technologists exploring the cutting edge of digital design — from generative workflows.Past presenters and partners include companies such as NVIDIA, NASA, New Balance, BMW, ARUP, Foster +, Partners, BIG, Autodesk, Dassault Systèmes, nTopology, PyhicsX, Neural Concept, Siemens and more, showcasing how computation and AI are transforming everything from aerospace to footwear.Learn more at https://cdfam.com This is a public episode. If you would like to discuss this with other subscribers or get access to bonus episodes, visit www.designforam.com