Spin-Off Foldcast: Paper Moulds for Concrete Construction

A 7×7-metre concrete slab held in a paper mould. It sounds implausible — yet this is what the spin-off company Foldcast is about to demonstrate, offering the construction industry a way to cut formwork and concrete use and carbon emissions by up to 40%. Prof. Ena Lloret Fritschi and Fabio Amicarelli founded Foldcast to bring this promise out of the labs of ETH Zurich and USI and into construction at scale.

The spin-off Foldcast was founded by Prof. Ena Lloret Fritischi and Fabio Amicarelli. Photo by USI Startup Centre

Hi Ena, Hi Fabio. What does Foldcast do, and how did the company come about?

Foldcast develops sustainable concrete building elements using digitally fabricated paper moulds. Instead of heavy timber or steel formwork, we use recyclable paper and cardboard to place concrete only where it is structurally needed — using up to 50% less material and achieving a 30–40% lower carbon footprint. Founded in 2024, the company builds on years of research at ETH Zurich, particularly the Smart Dynamic Casting project within the NCCR DFAB with Gramazio Kohler Research. There we discovered that formwork pressure can be nearly eliminated in controlled casting processes — leading to ultra-thin formworks and ultimately paper moulds. With Foldcast, we made a deliberate shift from complex material systems toward scalable, industry-ready solutions for slabs, façades, and staircases.

You founded the company in 2024. What has been happening since then?

Since its founding, Foldcast has evolved from academic research into real-world construction applications. The company has completed two full-scale demonstrators: SlabX, a structurally optimized precast concrete slab developed with a leading Swiss manufacturer, and Vertebra, a customizable modular concrete staircase assembled directly on site. In parallel, the team has developed a software prototype that automates the design and fabrication of the paper moulds. We have also received major awards and secured early investment.

The paper mould is being removed from the staircase element. Photo by Foldcast

Ena, you have been engaged within the NCCR DFAB for years, focusing on robotic slipforming with concrete. How does Foldcast relate to this research?

Foldcast builds directly on the Smart Dynamic Casting project — an interdisciplinary collaboration with Professor Robert Flatt and Gramazio Kohler Research at ETH Zurich. There we discovered that formwork pressure can be nearly eliminated in controlled casting processes, which led to ultra-thin formworks like Eggshell and ultimately to paper moulds. With Foldcast, we made a deliberate shift away from SDC's highly specialised, set-on-demand concrete systems — which still face hurdles for large-scale adoption — toward accessible technologies that can create impact sooner.

Smart Dynamic Casting aims at removing the need of individual made formwork for the construction of complex concrete structures. Photo by ETH Zürich

Who are you targeting with Foldcast — and why should concrete remain part of the future of construction?

We primarily work with real estate developers, general contractors, and precast manufacturers in Switzerland, Italy, and the DACH region. Concrete will remain the backbone of global construction for decades due to its availability, durability, and affordability. Our goal is not to replace it, but to use it more efficiently through better design and digital fabrication. By optimizing structural geometries and using recyclable paper moulds, concrete can achieve the same structural performance with significantly less material, enabling concrete structures that are both environmentally responsible and architecturally expressive.

Beyond carbon reduction, are there other sustainability benefits — and what challenges have you faced?

Our paper moulds are fully recyclable and reusable, supporting circular economy principles. Their lightweight nature reduces transportation impacts, and software-driven fabrication minimises waste during production. Prefabrication in controlled environments further improves quality. The main challenge is not technical but cultural: the construction sector is traditionally conservative. We have also had to balance architectural freedom with industrial scalability — ensuring customised solutions remain cost-competitive and simple to implement on site. Through pilot projects, partnerships with stakeholders, and continuous testing, we are gradually overcoming these barriers and preparing for industrial scalability.

What is the most exciting part of working at Foldcast right now?

We are entering the phase where research becomes reality. We are currently working on a 7×7-metre concrete slab for a NCCR DFAB project at ETH Zurich — a milestone demonstrating that paper formwork works at full building scale. In parallel, we are expanding our software tools and product catalogue in preparation for industrial deployment.

---

Get in contact with Foldcast: Fabio Amicarelli, fabio.amicarelli@foldcast.com

Visit Foldcast's website: https://foldcast.com/

Connect with Foldcast on LinkedIn: https://www.linkedin.com/compa...