Concrete Proof: How We 3D Printed Custom Pool Stool Forms

In construction, "custom" usually translates to "expensive" and "slow." When you are dealing with complex curves or tapered geometry in concrete, traditional carpentry using plywood and timber becomes a time-consuming nightmare.

We recently worked on a project that perfectly illustrates why Large Format Additive Manufacturing (LFAM) is changing the game for concrete forming: a set of custom reinforced concrete Pool Stools.

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The Challenge: The "Pool Stool"

The client needed forms to cast three concrete stools that would sit permanently in a pool area. The design wasn't a simple cylinder; it required:

• Complex Integration: A vertical rise transitioning into an angled flare to support a stone coping and acrylic top.
• Specific Tolerances: It needed to accommodate 1-inch glass tile and fit a precise mounting post (11 1/4" Inner Diameter).
• Urgency: The construction schedule was tight ("schedule shuffle"), and the forms were needed onsite immediately.

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The Pivot: Why 3D Printing Wins Over Wood

The real power of 3D printing isn't just in making the first part—it’s in how fast you can make the second version when plans change.

We initially modeled and printed the forms with a 15-inch top diameter. However, after reviewing the physical size, the client realized they were too large for the space and needed to scale down to a 13-inch diameter.

If these forms were being built by a carpenter:

• The existing wood forms would be scrap.
• Material would need to be re-purchased.
• Labor would start from zero, doubling the cost and delaying the pour by days.

With 3D Printing: We simply adjusted the CAD parameters to reduce the flare to 13 inches, adjusted the angle to compensate for the height, and sent the new files to the printers.

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The Result

Despite the mid-stream redesign and the requirement to reprint all three units, we were able to:

1. Iterate Instantly: We updated the design and got approval within hours.
2. Meet the Budget: We worked with the client to find a production solution that made financial sense, even with the re-print.
3. Deliver Fast: We went from a design change on Monday to having the finished forms ready for pickup by the weekend.

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Technical Specs

• Application: Sacrificial/Single-use Concrete Formwork.
• Dimensions: ~30" Height, tapered from 11.25" ID to 13" OD.
• Material: Large-nozzle extrusion for high-speed printing and wall rigidity to withstand concrete hydrostatic pressure.

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Need Custom Concrete Forms?

Whether you need complex architectural details, custom coping, or unique structural shapes, Morin 3D can print the forms you need faster than you can build them out of wood.

Don’t let custom geometry slow down your pour.

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