ZAVHY's ROBOTICS SOLUTIONS
Pioneering the future of construction with cutting-edge Robotics Solutions
Pioneering the future of construction with cutting-edge Robotics Solutions
Zavhy's 3DCP (3D Concrete Printing) technology revolutionises modern construction with advanced 3D printers tailored for large-scale concrete projects. Equipped with state-of-the-art robotic arms or gantry systems and specialised nozzles, it ensures precise, consistent concrete extrusion. Renowned for durability and reliability, Zavhy’s hardware integrates intelligent monitoring and customisable software for optimised printing. This innovative approach enables seamless workflow integration, rapid prototyping, scalability, and resource efficiency, empowering builders to create sustainable, custom structures.
3D Concrete Printing ECOSYSTEM BY ZAVHY
Pioneering the future of construction with intelligent and integrated 3DCP technologies
Zavhy’s Z-slicer
Zavhy’s Z-Slicer is a powerful and intuitive software tool that transforms 3D geometries into continuous robotic toolpaths, directly readable by Zavhy’s advanced 3D printing systems. With an easy-to-use graphical interface, users can apply textures, either locally or globally, manage entire printing sessions, and combine multiple objects in a single print job to optimise productivity. Z-Slicer enhances traceability and generates comprehensive reports, making it ideal for industrial and architectural applications. A key innovation is its integrated print-on-demand capability: the slicer analyses geometrical requirements and automatically determines the precise type and amount of material needed, such as fibres, aggregates, or mortar, adapting deposition across the print as needed. When paired with Zavhy’s FRED 4K multi-material printhead, capable of handling diverse materials and mixes simultaneously, the system offers unparalleled flexibility. This combination enables the fabrication of highly complex, customised geometries that are not achievable with traditional 3DCP technologies, setting a new industry benchmark.
Zavhy’s predictive tool
Zavhy’s predictive modeling tool offers a comprehensive printability assessment, enabling users to evaluate whether a designed object is likely to succeed or fail before printing begins. By identifying potential issues early, the tool helps users refine their geometries, reducing costly trial-and-error iterations and avoiding failed prints. It predicts failures not only in the fresh (wet) phase, such as buckling or deformation, but also in the hardened phase, where problems like poor interlayer bonding may occur. Built upon Zavhy’s extensive experimental research, the tool incorporates validated data from real-world printing and mechanical testing, allowing users to benefit from Zavhy’s hard-earned knowledge and achieve a “first-time-right” print experience. Printability is assessed using Finite Element Modeling (FEM) computed at early-age, capturing key failure modes like buckling, overstresses, and shrinkage. These simulations are based on time-dependent material properties, accurately reflecting real-world behaviour. Beyond simulation, the tool helps optimise process parameters for maximum print speed without compromising quality or structural integrity.
Zavhy’s control system
Zavhy’s user-friendly printing control interface empowers operators to configure and manage advanced 3D printing parameters through an Intuitive Human-Machine Interface (HMI). This interface is designed with a strong emphasis on usability and accessibility, and can be projected across various devices, such as tablets, laptops, or smart displays, offering flexibility and convenience on the shop floor or remotely. The system employs a step-by-step guidance approach, walking operators through each stage of the printing process, from initial setup and calibration to execution and shutdown. It simplifies complex tasks, making it easier for both novice and experienced users to operate the system efficiently. In addition, the interface includes built-in diagnostic and troubleshooting tools that assist in identifying and resolving issues in real time, minimising downtime and reducing the risk of print errors. By combining intuitive controls with intelligent support features, Zavhy’s interface enhances operational efficiency, reduces human error, and ensures a smoother, more reliable 3DCP experience.
Zavhy’s supervisory control
Zavhy’s supervisory control system incorporates a comprehensive real-time monitoring framework supported by a network of integrated sensors that continuously track critical parameters throughout the 3DCP process. These include material flow rate, layer height, nozzle speed, and ambient environmental conditions. The system provides operators with actionable insights into how these variables interact and impact the quality and consistency of the printed structure. Real-time feedback allows for proactive control, enabling swift adjustments to maintain optimal printing performance. The system enhances quality assurance by detecting deviations from predefined tolerances and issuing immediate alerts or corrective recommendations, helping prevent print defects and structural inconsistencies. Beyond the printing phase, the system continues to provide value during the post-print hardening stage, offering diagnostic information to identify potential anomalies that could compromise structural integrity. This ensures that the final printed elements not only meet engineering and safety standards but also achieve long-term durability and performance reliability.
FRED 4K printhead
The FRED 4K (Fibre Reinforced Extrusion Device) is Zavhy’s advanced patented printhead system for robotic 3DCP. It enables on-demand, multi-material extrusion by mixing aggregates, fibres, chemicals, and mortar near the nozzle. Equipped with multiple sensors, FRED 4K monitors and controls key parameters to ensure precise and consistent fibre-reinforced concrete (FRC) printing. Combined with Zavhy’s Z-slicer software, it allows for the creation of complex geometries unachievable by traditional methods. The system includes a mortar mixer, aggregate/fibre/chemical dosing units, and can be integrated with various robotic platforms, robotic arms, gantries, or crawlers, for a fully automated and flexible 3DCP setup. FRED 4K ensures seamless, high-precision construction workflows through real-time material monitoring and adaptive control of the 3DCP process.
RED system
Zavhy’s patented RED (Reinforcement Entrainment Device) system enhances the structural integrity of 3D printed concrete by automatically embedding multiple steel cables during printing. Designed to integrate with the FRED 4K printer as an add-on, the RED system works in tandem with Zavhy’s print head technology to enable simultaneous printing of fibre-reinforced concrete and steel reinforcement. Each cable is fed through independently controlled units, allowing precise speed adjustments, particularly in curved paths. Integrated sensors monitor feed speed, slippage, and cutting accuracy, ensuring consistent reinforcement placement. Automated cutting units allow the steel cables to be severed at designated points without manual input. The nozzle, available in various shapes and orientations, such as downflow, backflow, or hybrid, can handle complex geometries and organic forms with small radii. A central control unit coordinates all functions to deliver a fully automated, accurate, and structurally optimised 3DCP process that meets essential reinforcement standards for construction applications.
FIDO Tech
Zavhy’s patented fibre dosing unit, FIDO Tech, is a precision-engineered system developed for low, accurate dosing of various macro fibres into Zavhy’s FRED 4K printhead, enabling advanced fibre-reinforced concrete printing (FRCP). Designed for performance and reliability, FIDO Tech features a rotating drum that stores fibres in bulk and uses internal collectors to lift and discharge controlled portions onto a conveyor belt. These fibres are transported to a dosing chamber equipped with weight sensors and an actuator-controlled outlet. A central control unit governs drum speed, transport rate, and dosing intervals, ensuring consistent and clog-free fibre delivery. The system dynamically corrects dosing deviations and supports in-operation refilling for uninterrupted workflow. Optional sensors enhance automation, and full remote control is enabled via Zavhy’s HMI system, eliminating the need for manual intervention. FIDO Tech’s precise, near-continuous fibre dosing significantly improves mix homogeneity and structural performance, solving key limitations of conventional reinforcement in 3DCP.
AGGRIMATE SYSTEM
Zavhy’s automated aggregate dosing unit, the Aggrimate system, is a precision-engineered solution designed for accurate, low-rate dosing of diverse concrete filler particles, such as aggregates, hemp, cork and other bio based pellets, into Zavhy’s FRED 4K printhead, enabling true multi-material 3DCP (MM3DCP) on demand. The system features a screw conveying mechanism integrated with a bulk storage silo, where internal collectors discharge controlled portions onto the conveyor. Equipped with weight sensors and an actuator-controlled outlet, Aggrimate ensures precise outflow monitoring and alerts users via Zavhy’s HMI control interface when refilling is required. A central control unit regulates the screw rotation speed, transport flow, and dosing intervals, enabling clog-free, continuous operation. Additional sensor options allow for increased automation, while full remote control via Zavhy’s HMI eliminates the need for manual intervention. By delivering consistent, homogeneous filler dosing, the Aggrimate system addresses key limitations of traditional mortar-based 3DCP, paving the way for shrinkage-free, structurally enhanced printable concrete.
Chemion Tech
Zavhy’s Chemion Tech is a precision chemical injection system designed for the FRED 4K printhead, enabling accurate low-volume dosing of additives into Zavhy’s TACO₂CRETE 3D printing concrete. Using a progressive cavity pump, it delivers precise dosing from 0.06 to 1,000 l/h at up to 24 bar pressure with valveless, low-slip flow control, ensuring efficient performance and reduced component wear. Chemion features a flow sensor, actuator-controlled outlet, and a central unit that manages flow speed and intervals for consistent, clog-free injection. The system automatically corrects dosing deviations and allows for in-operation refills to maintain continuous workflow. Maintenance is simple and predictable, thanks to minimal components. Optional sensors increase automation, and full remote operation via Zavhy’s HMI system eliminates manual oversight. By ensuring precise, continuous dosing, Chemion Tech enhances mix homogeneity and improves concrete quality, addressing key limitations of traditional 1K concrete printing systems and advancing performance in large-scale 3DCP.
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