Search Results (81)

Current research and technical standards primarily rely on observational methods to evaluate the printability of 3D printing materials. There is a lack of quantitative assessment metrics for extrudability and supportability, and experimental data cannot be used to characterize extrudability and buildability. Further research is needed. Based on traditional workability parameters (such as flowability), this study explored the influence of printability characteristics and adopted two quantitative indicators—extrusion uniformity and cumulative deformation rate—to comprehensively evaluate material performance from two aspects, while observing the trend of changes in traditional workability indicators and print quality under experimental conditions. The experimental results showed that the extrusion uniformity of 3D-printed mortar initially improved and then gradually deteriorated as flowability increased, and was inversely proportional to dynamic yield stress. The cumulative deformation rate decreases with the improvement of height retention capability and the increase in static yield stress. Through parameter analysis, the optimal printing performance conditions were determined: when the extrusion uniformity is below 3.3% and the cumulative deformation rate is ≤6%, the corresponding dynamic yield stress range is 200 Pa to 800 Pa, and the static yield stress range is 1800 Pa to 3300 Pa. Under these parameters, the mortar exhibits excellent printing performance, including high-layer stacking capability (≥30 layers) and enhanced structural stability. This experiment demonstrates that using these two quantitative indicators can simply and efficiently evaluate the performance metrics of 3D-printed materials, while also revealing the relationship between the workability and printing quality of 3D-printed recycled micro-powder geopolymer materials. Full article

The use of 3D printing holds significant promise to transform the construction industry by enabling automation and customization, although key challenges remain—particularly the control of fresh-state rheology. This study presents a novel formulation that combines potassium-rich biomass fly ash (BFAK) with an air-entraining plasticizer (APA) to optimize the rheological behavior, hydration kinetics, and structural performance of mortars tailored for extrusion-based 3D printing. The results demonstrate that BFAK enhances the yield stress and thixotropy increases, contributing to improved structural stability after extrusion. In parallel, the APA adjusts the viscosity and facilitates material flow through the nozzle. Isothermal calorimetry reveals that BFAK modifies the hydration kinetics, increasing the intensity and delaying the occurrence of the main hydration peak due to the formation of secondary sulfate phases such as Aphthitalite [(K₃Na(SO₄)₂)]. This behavior leads to an extended setting time, which can be modulated by APA to ensure a controlled processing window. Flowability tests show that BFAK reduces the spread diameter, improving cohesion without causing excessive dispersion. Calibration cylinder tests confirm that the formulation with 1.5% APA and 2% BFAK achieves the maximum printable height (35 cm), reflecting superior buildability and load-bearing capacity. These findings underscore the novelty of combining BFAK and APA as a strategy to overcome current rheological limitations in digital construction. The synergistic effect between both additives provides tailored fresh-state properties and structural reliability, advancing the development of a sustainable SMC and printable cementitious materials. Full article

Additive manufacturing (AM) has brought significant breakthroughs to the construction sector, such as the ability to fabricate complex geometries, enhance efficiency, and reduce both material usage and construction waste. However, several challenges must still be addressed to fully transition from conventional construction practices to innovative and sustainable green alternatives. This study investigates the use of non-cementitious traditional mixtures for green construction applications through 3D printing using Liquid Deposition Modeling (LDM) technology. To explore the development of mixtures with enhanced physical and mechanical properties, natural pine and cypress wood shavings were added in varying proportions (1%, 3%, and 5%) as sustainable additives. The aim of this study is twofold: first, to demonstrate the printability of these eco-friendly mortars that can be used for conservation purposes and overcome the challenges of incorporating bio-products in 3D printing; and second, to develop sustainable composites that align with the objectives of the European Green Deal, offering low-emission construction solutions. The proposed mortars use hydrated lime and natural pozzolan as binders, river sand as an aggregate, and a polycarboxylate superplasticizer. While most studies with bio-products focus on traditional methods, this research provides proof of concept for their use in 3D printing. The study results indicate that, at low percentages, both additives had minimal effect on the physical and mechanical properties of the tested mortars, whereas higher percentages led to progressively more significant deterioration. Additionally, compared to molded specimens, the 3D-printed mortars exhibited slightly reduced mechanical strength and increased porosity, attributable to insufficient compaction during the printing process. Full article

Nowadays, 3D printing has revolutionized the construction and building industry, enabling researchers to push the boundaries of creating structural components with this innovative technique. A key factor for the success of this approach lies in selecting the optimal mix design, which must possess suitable properties for printing while ensuring strong performance once hardened. However, achieving this optimal mix is complex due to limited knowledge regarding the necessary fresh-state properties, the characteristics and proportions of the constituents, the influence of printing parameters on these properties, and the various challenges encountered during and post printing. This paper aims to address these aspects by offering a comprehensive review of the steps researchers have taken to develop an optimized 3D printable mix. Full article

There is no doubt that additive manufacturing (AM) with mortars presents an opportunity within the framework of a circular economy that should not be overlooked. The concepts of reduce, reuse, and recycle are fully aligned with this technology. One of the less explored possibilities is the utilisation of mining tailings as aggregates in printing mortars. This idea not only incorporates the concept of recycling but also contributes to a reduction in the production of potentially hazardous waste that would otherwise require storage in dams, thereby decreasing long-term environmental risks and improving the management of mineral resources. We employed a mortar composed of 12.5% material derived from mining tailings to highlight aspects of AM that are typically not subject to analysis, such as the necessity of considering contact interfaces between layers in structural design, the stackability of layers during the construction process, and the behaviour under fire and seismic events, which must be taken into account during the operational phase. Without aiming for exhaustiveness, we conducted a series of tests and computational modelling to show the significance of these factors, with the intention of drawing the attention of different stakeholders—including construction companies, regulatory authorities, standardisation agencies, insurers, and end-users. Full article

3D printing with concrete has been accounted as a foremost strategy to mitigate low productivity, workforce shortage, and high waste generation in the construction industry. However, substantial environmental impacts related to high cement content in printable mixtures have received minor concern so far. An interesting prospect is the use of recycled concrete powders (RCP) to decrease cement content through their fineness and high specific surface area, which can potentially enhance rheological properties for 3D printing. However, their effects on cementitious mixtures greatly depend on their origin. This research investigated two distinct RCPs to replace 50% of Portland cement in pastes. On cementitious pastes, rotational rheometry, isothermal calorimetry, and a Life Cycle Inventory assessment were conducted. Printability tests on mortars evaluated the effects of RCP on extrudability and buildability. The results showed intensified early hydration for RCP pastes and up to a three-fold increase in static yield stress and higher dynamic yield stresses, regardless of origin. The viscosity of RCP pastes varied in relation to packing density. Extrudability and buildability can be compromised using RCP due to higher yield stress. The LCI assessment indicated a potential decrease of up to 62% in CO₂ emissions using RCPs. Therefore, if adequate rheological adjustments are employed in the mix design of RCP mixtures, this material emerges as a feasible strategy to formulate 3D printable mixtures with a lower environmental footprint. Full article

Concrete printing in three dimensions is believed to be an innovative construction method. Numerous researchers conducted laboratory experiments over the past decade to examine the behavior of concrete mixtures and the material properties that are pertinent to the 3D concrete printing industry. Furthermore, the global warming effect is being further exacerbated by the increased use of cement, which increases carbon dioxide (CO₂) emissions and pollution. Various standards endorse the utilization of Portland-composite cement in construction to mitigate CO₂ emissions, particularly cement CEM II/A-P. This research provides an experimental and numerical study to examine the evolution of cementitious composite utilizing cement CEM II/A-P for three-dimensional concrete printing, combining three different types of synthetic fiber. The thorough experimental analysis includes three combinations integrating diverse fiber types (polypropylene, high-modulus polyacrylonitrile, and alkali-resistant glass fibers) alongside a reference mixture devoid of fiber. The three distinct fiber types in the mixtures (polypropylene, high modulus polyacrylonitrile, and alkali-resistant glass fibers) were evaluated to assess their impact on (i) the flowability of the cementitious mortar and the slump flow test of fresh concrete, (ii) the concrete compressive strength, (iii) the uniaxial tensile strength, (iv) the splitting tensile strength, and (v) the flexural tensile strength. Previous researchers designed a cylinder stability test to determine the shape stability of the 3D concrete layers and their capacity to support the stresses from subsequent layers. Furthermore, the numerical analysis corroborated the experimental findings with the finite element software ANSYS 2023 R2. The flexural performance of the examined beams was validated using the Menetrey–Willam constitutive model, which has recently been incorporated into ANSYS. The experimental data indicated that the incorporation of synthetic fiber into the CEM II/A-P mixtures enhanced the concrete’s compressive strength, the splitting tensile strength, and the flexural tensile strength, particularly in combination including alkali-resistant glass fibers. The numerical results demonstrated the efficacy of the Menetrey–Willam constitutive model, featuring a linear softening yield function in accurately simulating the flexural behavior of the analyzed beams with various fiber types. Full article

This study investigates the fresh state and hardened state mechanical and durability properties of 3D-printed concrete. The mechanical tests focused on its anisotropic behavior in response to different load orientations. Compressive, flexural, and splitting tensile strengths were evaluated relative to the print layers orientation. Results showed that compressive strength varied significantly, achieving 85% of cast sample strength when the load was applied parallel to the print layers ([u] direction), 71% when the load was applied perpendicular to the print object’s side plane ([v] direction), while only reaching 59% when applied perpendicular to the top plane ([w] direction). Similar trends were observed for flexural strength, with average values reaching 75% of cast sample strength when the load was applied perpendicular to the print layers ([v.u] and [w.u] directions), but decreasing to 53% when the load was applied parallel to print layers ([u.w] direction), underscoring the weaknesses at interlayer interfaces. The splitting tensile strength remained relatively consistent across print orientations, reaching 90% of the cast sample strength. Durability assessment tests revealed that 3D-printed concrete exhibits reduced resistance to environmental factors, particularly at the layer interfaces where the cold joint was formed, which are prone to moisture penetration and crack formation. These findings contribute valuable insights into the mechanical and durability properties of 3D-printed concrete, emphasizing the importance of print orientation and interlayer bonding in its performance. This understanding helps guide the optimal use of 3D-printed elements in real-life applications by aligning load or exposure to environmental factors with the material’s strength and durability characteristics. Full article

Addressing the challenge of weak interface strength in 3D-printed mortars, this study introduces a novel technique using sinuous printing trajectories. The self-locking interface is formed by different meandering print trajectories, and the changes in the strength of the test interface are investigated by adjusting the trajectories to form different amplitudes. This ensures alignment of peaks and troughs between layers, aiming for enhanced interfacial cohesion. Experimental tests measured mechanical properties of printed mortar specimens with varying amplitudes. Using Digital Image Correlation technology, strain fields and fracture surfaces were analyzed. Initial results revealed a 28% decrease in shear resistance for side-by-side printed interfaces compared to traditional layered interfaces. As amplitude increased, shear load-bearing capacity improved. Specifically, a 15 mm amplitude saw a 40% rise in interlayer shear strength. However, a 20 mm amplitude led to reduced shear capacity, with even slight forces causing potential fractures. Tensile strength also increased with amplitude. Specimens up to 15 mm amplitude primarily followed the printing interface in fractures, while a 20 mm amplitude cut through mortar strips. Post-fracture analysis showed the highest surface irregularity at a 15 mm amplitude, aligning with tensile load-bearing capacity. Full article

The popularity of additive technologies in construction is increasing every year. At the same time, there are still a significant number of unresolved issues in this area related to the complexity of ensuring uniformity of printing due to technical difficulties with the mortar. One of the main issues is the adhesion of printed layers. This is especially true for continuing the printing process after it has been suspended with the formation of a cold joint. The authors consider the possibility of improving the technological properties of 3D construction printing (3DCP) mortars by introducing redispersible polymer powders (RPPs) and surface-active substances (SASs) into their composition. A comprehensive analysis of the effectiveness of various RPPs and SASs was carried out using standard testing methods to identify the most effective options and combinations of admixtures depending on their structure and mechanism of action. Laboratory tests of the mortar composition for 3DCP using the selected RPPs and SASs were carried out with the imitation of the formation of a cold joint. The most effective combination of RPPs and SASs was used to create the mortar for making the form-forming element using a construction 3D printer. Based on the results of the tests, the patterns of RPPs and SASs influence on the adhesive strength of such mixtures were determined. Full article

Three-dimensionally printed concrete is a transformative technology that addresses housing shortages due to population growth and enables innovative architectural designs. The objective of this study is to investigate the connection between a conventional test and the rheological properties of 3D-printed concrete. A more precise assessment of material quality based on traditional evaluation techniques is proposed. Standard tests are conducted to evaluate the consistency of 3D-printed concrete materials. Complementarily, a rheometer is employed to accurately measure key rheological properties, thereby establishing a link with empiric testing methodologies. The correlation between the flow table test and rheological coefficients, such as yield stress and viscosity, has been identified as the most effective in basic experiments for evaluating material behavior. This approach allows for a preliminary assessment of printability without the need for additional complex equipment. The study has successfully established a relationship between flow table tests and rheological parameters. However, further research involving a broader range of materials and print-test experiments is essential to enhance the correlation between other conventional testing methods and rheometer results. Full article

One challenge for 3D printing is that the mortar must flow easily through the printer nozzle, and after printing, it must develop compressive strength fast and high enough to support the layers on it. This requires an exact and difficult control of the superplasticizer (SP) dosing. Nanocrystalline cellulose (CNC) has gained significant interest as a rheological modifier of mortar by interacting with the various cement components. This research studied the potential of nanocrystalline cellulose (CNC) as a mortar aid for 3D printing and its interactions with SPs. Interactions of a CNC and SP with cement suspensions were investigated by means of monitoring the effect on cement dispersion (by monitoring the particle chord length distributions in real time) and their impact on mortar mechanical properties. Although cement dispersion was increased by both CNC and SP, only CNC prevented cement agglomeration when shearing was reduced. Furthermore, combining SP and CNC led to faster development of compressive strength and increased compressive strength up to 30% compared to mortar that had undergone a one-day curing process. Full article

Additive manufacturing (AM) technologies, including 3D mortar printing (3DMP), 3D concrete printing (3DCP), and Liquid Deposition Modeling (LDM), offer significant advantages in construction. They reduce project time, costs, and resource requirements while enabling free design possibilities and automating construction processes, thereby reducing workplace accidents. However, AM faces challenges in achieving superior mechanical performance compared to traditional methods due to poor interlayer bonding and material anisotropies. This study aims to enhance structural properties in AM constructions by embedding 3D-printed polymeric meshes in clay-based mortars. Clay-based materials are chosen for their environmental benefits. The study uses meshes with optimal geometry from the literature, printed with three widely used polymeric materials in 3D printing applications (PLA, ABS, and PETG). To reinforce the mechanical properties of the printed specimens, the meshes were strategically placed in the interlayer direction during the 3D printing process. The results show that the 3D-printed specimens with meshes have improved flexural strength, validating the successful integration of these reinforcements. Full article

Towards a sustainable future in construction, worldwide efforts aim to reduce cement use as a binder core material in concrete, addressing production costs, environmental concerns, and circular economy criteria. In the last decade, numerous studies have explored cement substitutes (e.g., fly ash, silica fume, clay-based materials, etc.) and methods to mimic the mechanical performance of cement by integrating polymeric meshes into their matrix. In this study, a systemic approach incorporating computer aid and biomimetics is utilized for the development of 3D-printed clay-based composite mortar reinforced with advanced polymeric bioinspired lattice structures, such as honeycombs and Voronoi patterns. These natural lattices were designed and integrated into the 3D-printed clay-based prisms. Then, these configurations were numerically examined as bioinspired lattice applications under three-point bending and realistic loading conditions, and proper Finite Element Models (FEMs) were developed. The extracted mechanical responses were observed, and a conceptual redesign of the bioinspired lattice structures was conducted to mitigate high-stress concentration regions and optimize the structures’ overall mechanical performance. The optimized bioinspired lattice structures were also examined under the same conditions to verify their mechanical superiority. The results showed that the clay-based prism with honeycomb reinforcement revealed superior mechanical performance compared to the other and is a suitable candidate for further research. The outcomes of this study intend to further research into non-cementitious materials suitable for industrial and civil applications. Full article

Based on 3D printing technology, this paper investigates the effects of the printing process and reinforcement materials on the performance of 3D-printed glass bead insulation mortar. In order to improve and enhance the performance of the mortar, two sets of tests were designed for research and analysis. Firstly, by changing the direction of the interlayer printing strips, the anisotropy of the specimens in different paths was analyzed, and then the effect of different dosages of different fibers on the performance of 3D-printed glass bead insulation mortar was investigated by adding reinforcing materials. The results show that the path a specimen in the X direction’s compressive strength is the best; in the Y direction, flexural strength is the best; the path b specimen in the Y direction’s compressive strength is the best; in the Z direction, flexural strength is the best, but the compressive and flexural strengths are lower than the strength of the specimen without 3D printing (cast-in-place specimen); and adding reinforcing materials mortar not only has high strength but also has good printability and excellent thermal insulation. This paper provides a theoretical basis and reference value for the popularization and application of 3D printing thermal insulation mortar technology. Full article