World’S First 3D Printed Footbridge From Waste Materials Completed

A groundbreaking prototype of “Da Vinci’s Bridge”, touted as the world’s first 3D printed bridge constructed from waste materials sourced from stone processing, has been completed after extensive research and experimentation over the past year.

The project, which integrates innovative technology with eco-sustainability, draws inspiration from one of Leonardo da Vinci’s ambitious designs – a self-supporting bridge intended to connect the Pera district with Constantinople across the Golden Horn.

Developed by the ArCoD department of the Polytechnic University of Bari, Italy, in partnership with leading firms in 3D printing and stone processing, the bridge signifies a noteworthy advancement in eco-friendly construction methods. The prototype measures approximately 6m in length and was designed as a pedestrian bridge, effectively reinterpreting da Vinci’s original vision to fulfill contemporary experimental needs.

A key feature of the project is the employment of a novel low-impact mortar made from waste stone powders combined with a lime-based binder, developed by the Italian start-up B&Y, led by Vincenzo Gurrado. This material exemplifies the potential for recycling waste materials in construction, a promising avenue for the industry. B&Y’s innovative approach integrates creativity with cutting-edge technology to transform processing by-products into functional construction materials.

Technical support for the 3D printing aspect was provided by the World’s Advanced Saving Project (WASP), an industry leader in sustainable additive manufacturing. WASP’s large-format 3D printer, the 3MT LDM Concrete, facilitated the construction of 13 individual blocks, which were then assembled by the University of Bari employing a temporary centring system. The design utilised principles of stereotomy – as per da Vinci’s original concept – to achieve a self-supporting structure.

The completion of the Da Vinci’s Bridge prototype sets the stage for future endeavours, with an emphasis on assessing the materials’ mechanical properties and improving the printing techniques. These developments could lead to broader applications within the architectural field, aligning with a vision for a more sustainable and technologically advanced approach to construction.

This project is credited to a multidisciplinary team, including Professor Giuseppe Fallacara from the Polytechnic University of Bari, architects Ilaria Cavaliere and Angelo Vito Graziano, and engineers from B&Y and WASP, all collaborating to advance the potential of additive manufacturing in eco-friendly construction practices.

Last year NCE did a deep dive on the potential for 3D printing to become mainstream in bridge construction, speaking to Cowi UK, Holcim, Imperial College London and Royal HaskoningDHV.

In the UK, last October saw the completion of a 3D printed footbridge at the Constructionarium in Norfolk.

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