Breaking the Mold: How Vertico’s Robot-on-Track System Is Redefining Concrete in Prefabricated Architecture
At the intersection of digital fabrication and architectural ambition, Vertico’s Robot-on-Track system offers a radical shift in how we shape concrete. Born from the need to break free of the geometric limits of traditional formwork, this advanced 3D printing technology reimagines prefab not as repetitive and rigid—but as expressive, scalable, and adaptive. From custom columns and freeform facades to urban furniture and pavilions, the system allows architects to explore curvature, complexity, and creativity in ways once considered impractical or cost-prohibitive. In this interview, Vertico shares how their robotic platform is empowering a new generation of designers to treat fabrication not as a constraint—but as a design opportunity.
How did the Robot on Track system originate, and what problem in construction or design was it initially created to solve?
The Robot-on-Track was developed to overcome the geometric and material constraints of traditional concrete construction. Conventional methods often limit designers to straight lines and flat surfaces due to the complexity, time, and cost of molds. Vertico recognized that robotic 3D printing could free concrete from these formwork limitations and open the door to a modern “Renaissance” in architecture – one where expressive, efficient forms are not only possible but practical.
A 6-axis Robot-on-Track with the combination of a 2-component Printhead (concrete+accelerant) unlocks the full possibilities of 3D Printing with concrete. This system is capable of printing long- span, high-volume, and complex geometries without compromising on precision. It was developed not just as a machine, but as a new design tool – one that empowers architects to dream beyond the right angle and
rethink what’s possible in modular and modern construction.
What makes the track-based robotic system fundamentally different from traditional 3D printing methods in terms of architectural scalability and flexibility?
One of the biggest advantages of printing on a track is size – not just of individual prints, but of the overall workflow. When you’re working on a complex modular project with many elements, the track system makes it possible to print multiple pieces in a single day. Since they can remain on the print bed to fully set, there’s no need to remove or relocate parts immediately after printing. This is especially useful when the elements are tall and difficult to handle.
This setup was particularly helpful in a project we completed in collaboration with Zaha Hadid Architects, where both time and output demands were intense. The combination of a wide print bed and the robot’s extended reach made it possible to keep up with the pace and precision the project required – it was a lifesaver.
Vertico Hub. 3D Printing Aevum
Here’s how the system stands out:
- Scalability: The robot arm has a 3.2-meter reach and moves along a 6–10 meter track. Longer tracks are possible depending on your available factory space. This setup enables printing of components over 10 meters wide and up to 2.5 meters tall.
- Flexibility: With its multi-axis robot and Accelerator Printhead, the system supports tool orientation and complex geometries – including cantilevers, overhangs, and non-planar designs.
Aevum. Milan Design Week 2025
This combination makes it possible to move beyond repetitive elements and truly embrace mass
customization – something that’s often talked about in architecture but rarely achievable at scale.
Which types of architectural forms or projects best showcase the design potential of this technology?
The system excels in printing non-standard, complex geometries that would be prohibitively expensive or labor-intensive using conventional methods:
Columns
Vertico specializes in printing concrete columns. Despite their intricate and modern shapes, these columns do not compromise on structural capabilities.
3D Printed Structural Columns. Vertico
Urban furniture, flower pots
From custom-designed benches to planters and playground edges, 3D printing allows for varied forms and seating heights without additional cost – a game-changer in inclusive, sustainable design.
Sandbox bench in Delft. Vertico
Freeform facades and wall elements
We’ve seen this potential realized in projects like a 3D printed house in Germany, realized by our client Staikos3D or the first-ever 3D concrete printed station in Japan, printed by Serendix, where freeform walls were integral to both the design language and the structural system. Moreover, it can be a modular design, where wall panels are printed on site and each of them is unique.
Pavilions
Compact architectural installations like pavilions are ideal for showcasing the possibilities of 3D concrete printing. Their freeform geometry, modularity, and sculptural character allow designers to experiment with structure and aesthetics in ways that would be too complex or costly with traditional methods. Projects like Hexastone demonstrate how 3D printing enables rapid fabrication of expressive, lightweight forms with minimal material use – perfect for exhibitions, public spaces, or prototyping novel design ideas.
Hexastone. Vertico
How do you see architects integrating this construction method into the early stages of design thinking and project development?
We encourage architects to see 3D printing not just as a production method, but as a design driver. Using tools like Grasshopper for parametric modeling, the robotic constraints and opportunities can inform the geometry from the earliest concept phase. This enables designers to think in terms of material efficiency, toolpath logic, and performance-driven forms. Collaboration between architecture and fabrication is essential – and at Vertico, we often co- develop projects with architects from the ground up to maximize both creative and structural potential.
Looking ahead, where is this technology heading—do you see it playing a role in modular prefabrication or large-scale urban construction?
Absolutely. The future lies in modular prefab systems that combine the design freedom of 3D printing with the efficiency of industrial construction. We’re already seeing interest in custom facade panels, and site-specific urban furniture. Our robots are being used in house printing, bridge prototypes, and public spaces. As the technology matures, we see it playing a central role in creating digitally fabricated, low-waste, high-performance components that redefine how cities are built.
