3D printed air traffic control tower model for Passenger Terminal Expo 2026
Zaha Hadid Architects’ Tech Lab successfully delivered a 6‑meter‑tall 3D printed model of an air traffic control tower for the ZHAviation exhibition booth at Passenger Terminal Expo 2026 in London.
The installation was based on an original tower design by ZHA and represents one of the Lab’s most technically ambitious fabrication projects to date.
3D printed fire-resistant PETG for exhibition safety
The project was developed and produced entirely in‑house using the Lab’s WASP HDP XL Extruder. In total, fifteen modular panels, each approximately one metre in height and width, were printed continuously over 270 hours using fire‑resistant PETG to meet exhibition safety requirements. Once printed, all components were internally fitted with programmable LED lighting, designed to animate the interior surface and enhance the tower’s sculptural geometry.
The completed panels were then mounted onto a structural metal framework, allowing the installation to be safely assembled within the exhibition hall and later disassembled for use in other exhibitions.
Robotic arm 3D printing for large-scale fabrication
This project marks the first major use of the Tech Lab’s newly installed second robot, enabling simultaneous multi‑robot fabrication. The team collaborated closely with WASP to extend their CEREBRO robotic control system, achieving – for the first time – successful multi‑robot integration within this setup.
This advancement significantly expands the Lab’s future capabilities in producing large‑scale architectural components through robotic 3D printing.
A project by Zaha Hadid Architects, 3D printed by ZHA Tech Lab
Photo credits: Zaha Hadid Architects