XXL concrete mold: Innovative design with 3D printed casting mold for concrete

The increasing demand for individual, large-format concrete parts – from façade elements to sculptures and designer furniture – requires efficient processes. Conventional molds made of wood or steel are often costly and time-consuming. With LFAM, on the other hand, 3D printed casting molds for concrete can be produced automatically and precisely. Find out below how you can optimize your processes with an LFAM XXL concrete casting mold and why Hänssler is the right partner for casting molds for concrete.

3D casting mold for concrete: What are design concrete parts?

Facade elements with 3D patterns
Sculptures, art objects and exposed concrete furniture
Planters, lights, acoustic and privacy screen elements

This results in high demands on concrete casting molds: exact tolerances, smooth surfaces, variable wall thicknesses and much more. Thanks to the innovative combination printing/milling process, Hänssler LFAM technology offers the necessary precision for exclusive concrete parts.

XXL casting mold vs. conventional concrete mold or formwork molds

Wood/multiplex and steel formwork must be laboriously glued, screwed, machined or welded. This results in long throughput times, high costs and little design freedom. The advantages of LFAM technology clearly outweigh the disadvantages. Fast implementation thanks to purely digital data processing and production. Complex free-form surfaces are easy to implement and there is no need to manually assemble wooden layers or the mold itself. XXL concrete casting mold – with LFAM, the finished component is produced much faster!

Concrete mold & formwork molds using LFAM: how it works

LFAM (Large Format Additive Manufacturing) stands for large-format 3D printing using the fused deposition modeling process:

Construction volume 2,600 × 1,700 × 950 mm → XXL concrete casting mold
Combination process printing & milling → perfect surfaces for exposed concrete
Thermoplastics (PLA, ABS, PC, PET, PP, PA, TPU) optionally with glass fiber or carbon fiber
Close-contour printing for material and energy efficiency
High precision even with XXL shapes

Result: Reusable and accurately fitting casting molds in all desired dimensions with a high degree of freedom.

XXL concrete casting mold: Your advantages at a glance

Fast iterations: CAD adjustments in just a few minutes
Complex geometries with free-form surfaces can be implemented
Reduced set-up and assembly times
Sustainability thanks to minimal waste during machining
High reproducibility in series production
Longevity

Casting molds for concrete and concrete molds for formwork: Why Hänssler?

Comprehensive advice from the idea to series production

We support you both strategically and technically – from the first sketch to the final implementation of your project.

CAD design of your beton XXL casting mold

Using modern CAD technology, we develop precise molds for large-scale concrete components.

In-depth material and processing expertise

Benefit from our in-depth understanding of materials and their optimal processing in practice.

Fast, flexible production thanks to 40 years of experience

Many years of experience enable us to efficiently meet even short-term requirements.

Reference projects in architecture, art and industrial construction

Whether buildings, sculptures, or industrial applications – our solutions set new standards.

Sustainability

Production with 100% certified green electricity

Use of recycled thermoplastics

Less chip waste due to printing of a near-contour blank

Shorter supply chains due to the elimination of a semi-finished product

Conclusion

With LFAM, you can revolutionize the production of a concrete casting mold and formwork mould. Increase your process speed, reduce costs and gain maximum design freedom. Hänssler Kunststoff- und Dichtungstechnik provides you with expert support from the first sketch to series production.