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PRECAST CONCRETE ELEMENTS164 CPI %u2013 Concrete Plant International %u2013 6 | 2025 www.cpi-worldwide.comThe processing of the FlexCore R&D project along the solution path set out in the application went according to plan. All milestones in the project were achieved. Scientific questions for solving the technical risks were fundamentally developed and solved. The project results are promising and show both the potential for the application of 3D printing and downstream milling in the fresh and hardened state as well as for a new formwork technology to expand geometric complexities such as the avoidance of demoulding bevels or the integration of undercuts in the concrete element.Sustainability through recyclingAnother milestone of the project is the recycling concept developed. Milling waste and used formwork elements are not disposed of, but processed and reused as aggregates.Studies have shown that up to 50 % of the rock flours can be easily replaced by recycled material. The flexural strength even increases slightly in this area. In addition, waste streams are significantly reduced %u2013 a plus for the environment and costs. This means that the material cycle can be almost completely closed.Construction of the formwork by combining the concrete elements with the wooden core (left) and subsequent production of the flexible core element (right). The formwork is filled with polyurethane. The resulting PU component can then be used together with the formwork core as a flexible formwork element to produce a precast concrete element. Demoulding of the flexible core element (left) and overview of all formwork elements used (right)