1. Department of Civil Engineering, Qingdao University of Technology, Qingdao 266000, China 2. Innovation Institute for Sustainable Maritime Architecture Research and Technology, Qingdao University of Technology, Qingdao 266000, China 3. Intelligent Construction Lab, Qingdao University of Technology, Qingdao 266000, China 4. Shandong Zhaojin Industrial Development Co., Ltd., Yantai 264000, China 5. Architectural Engineering Institute, Weifang Engineering Vocational College, Weifang 261000, China 6. Qingjian Group Co., Ltd., Qingdao 266000, China 7. College of Architecture and Urban Planning, Qingdao University of Technology, Qingdao 266000, China 8. Department of Structural Engineering and Building Materials, Ghent University, Ghent 9000, Belgium 9. Institute of Building Materials, ETH Zurich, Zurich 8064, Switzerland
The importance of geometrical control of three dimensional (3D) printable concrete without the support of formwork is widely acknowledged. In this study, a numerical model based on computational fluid dynamics was developed to evaluate the geometrical quality of a 3D printed layer. The numerical results were compared, using image analysis, with physical cross-sectional sawn samples. The influence of printing parameters (printing speed, nozzle height, and nozzle diameter) and the rheological behavior of printed materials (yield stress), on the geometrical quality of one printed layer was investigated. In addition, the yield zone of the printed layer was analyzed, giving insights on the critical factors for geometrical control in 3D concrete printing. Results indicated that the developed model can precisely describe the extrusion process, as well as the cross-sectional quality.
T Wangler, R Pileggi, S Gürel, R J Flatt. A chemical process engineering look at digital concrete processes: Critical step design, inline mixing, and scaleup. Cement and Concrete Research, 2022, 155: 106782 https://doi.org/10.1016/j.cemconres.2022.106782
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V Mechtcherine, K van Tittelboom, A Kazemian, E Kreiger, B Nematollahi, V N Nerella, M Santhanam, G de Schutter, G van Zijl, D Lowke, E Ivaniuk, M Taubert, F Bos. A roadmap for quality control of hardening and hardened printed concrete. Cement and Concrete Research, 2022, 157: 106800 https://doi.org/10.1016/j.cemconres.2022.106800
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Y Tao, K Lesage, K Van Tittelboom, Y Yuan, G de Schutter. Twin-pipe pumping strategy for stiffening control of 3D printable concrete: From transportation to fabrication. Cement and Concrete Research, 2023, 168: 107137 https://doi.org/10.1016/j.cemconres.2023.107137
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L Gebhard, L Esposito, C Menna, J Mata-Falcón. Inter-laboratory study on the influence of 3D concrete printing set-ups on the bond behaviour of various reinforcements. Cement and Concrete Composites, 2022, 133: 104660 https://doi.org/10.1016/j.cemconcomp.2022.104660
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T Marchment, J Sanjayan. Reinforcement method for 3D concrete printing using paste-coated bar penetrations. Automation in Construction, 2021, 127: 103694 https://doi.org/10.1016/j.autcon.2021.103694
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G Ma, R Buswell, W R Leal da Silva, L Wang, J Xu, S Z Jones. Technology readiness: A global snapshot of 3D concrete printing and the frontiers for development. Cement and Concrete Research, 2022, 156: 106774 https://doi.org/10.1016/j.cemconres.2022.106774
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M K Mohan, A V Rahul, G de Schutter, K Van Tittelboom. Extrusion-based concrete 3D printing from a material perspective: A state-of-the-art review. Cement and Concrete Composites, 2021, 115: 103855 https://doi.org/10.1016/j.cemconcomp.2020.103855
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Y Weng, M Li, S Ruan, T N Wong, M J Tan, K L Ow Yeong, S Qian. Comparative economic, environmental and productivity assessment of a concrete bathroom unit fabricated through 3D printing and a precast approach. Journal of Cleaner Production, 2020, 261: 121245 https://doi.org/10.1016/j.jclepro.2020.121245
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J Xiao, S Zou, Y Yu, Y Wang, T Ding, Y Zhu, J Yu, S Li, Z Duan, Y Wu, L Li. 3D recycled mortar printing: System development, process design, material properties and on-site printing. Journal of Building Engineering, 2020, 32: 101779 https://doi.org/10.1016/j.jobe.2020.101779
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Y Tao, G Vantyghem, K Lesage, Y Yuan, W D Corte, K V Tittelboom, G D Schutter. Adhesion properties of printable polymer-modified concrete for rock tunnel linings. ACI Materials Journal, 2021, 118(6): 61–73 https://doi.org/10.14359/51733105
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G de Schutter, K Lesage, V Mechtcherine, V N Nerella, G Habert, I Agusti-Juan. Vision of 3D printing with concrete—Technical, economic and environmental potentials. Cement and Concrete Research, 2018, 112: 25–36 https://doi.org/10.1016/j.cemconres.2018.06.001
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R A Buswell, W R Leal de Silva, S Z Jones, J Dirrenberger. 3D printing using concrete extrusion: A roadmap for research. Cement and Concrete Research, 2018, 112: 37–49 https://doi.org/10.1016/j.cemconres.2018.05.006
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B Lu, Y Weng, M Li, Y Qian, K F Leong, M J Tan, S Qian. A systematical review of 3D printable cementitious materials. Construction and Building Materials, 2019, 207: 477–490 https://doi.org/10.1016/j.conbuildmat.2019.02.144
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S A O Nair, S Panda, M Santhanam, G Sant, N Neithalath. A critical examination of the influence of material characteristics and extruder geometry on 3D printing of cementitious binders. Cement and Concrete Composites, 2020, 112: 103671 https://doi.org/10.1016/j.cemconcomp.2020.103671
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S BhattacherjeeM Santhanam. Enhancing buildability of 3D printable concrete by spraying of accelerating admixture on surface. In: Proceedings of Second RILEM International Conference on Concrete and Digital Fabrication: Digital Concrete 2020. Eindhoven: Springer, 2020
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Y Tao, Q Ren, K Lesage, K van Tittelboom, Y Yuan, G de Schutter. Shape stability of 3D printable concrete with river and manufactured sand characterized by squeeze flow. Cement and Concrete Composites, 2022, 133: 104674 https://doi.org/10.1016/j.cemconcomp.2022.104674
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R Comminal, W R Leal da Silva, T J Andersen, H Stang, J Spangenberg. Modelling of 3D concrete printing based on computational fluid dynamics. Cement and Concrete Research, 2020, 138: 106256 https://doi.org/10.1016/j.cemconres.2020.106256
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A V Rahul, M K Mohan, G De Schutter, K van Tittelboom. 3D printable concrete with natural and recycled coarse aggregates: Rheological, mechanical and shrinkage behaviour. Cement and Concrete Composites, 2022, 125: 104311 https://doi.org/10.1016/j.cemconcomp.2021.104311
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Q Yuan, Z Li, D Zhou, T Huang, H Huang, D Jiao, C Shi. A feasible method for measuring the buildability of fresh 3D printing mortar. Construction and Building Materials, 2019, 227: 116600 https://doi.org/10.1016/j.conbuildmat.2019.07.326
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R Buswell, J Xu, D de Becker, J Dobrzanski, J Provis, J T Kolawole, P Kinnell. Geometric quality assurance for 3D concrete printing and hybrid construction manufacturing using a standardised test part for benchmarking capability. Cement and Concrete Research, 2022, 156: 106773 https://doi.org/10.1016/j.cemconres.2022.106773
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N Roussel, J Spangenberg, J Wallevik, R Wolfs. Numerical simulations of concrete processing: From standard formative casting to additive manufacturing. Cement and Concrete Research, 2020, 135: 106075 https://doi.org/10.1016/j.cemconres.2020.106075
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A Perrot, A Pierre, V N Nerella, R J M Wolfs, E Keita, S A O Nair, N Neithalath, N Roussel, V Mechtcherine. From analytical methods to numerical simulations: A process engineering toolbox for 3D concrete printing. Cement and Concrete Composites, 2021, 122: 104164 https://doi.org/10.1016/j.cemconcomp.2021.104164
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J Reinold, V N Nerella, V Mechtcherine, G Meschke. Extrusion process simulation and layer shape prediction during 3D-concrete-printing using the particle finite element method. Automation in Construction, 2022, 136: 104173 https://doi.org/10.1016/j.autcon.2022.104173
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R J M Wolfs, F P Bos, T A M Salet. Early age mechanical behaviour of 3D printed concrete: Numerical modelling and experimental testing. Cement and Concrete Research, 2018, 106: 103–116 https://doi.org/10.1016/j.cemconres.2018.02.001
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G Vantyghem, T Ooms, W de Corte. VoxelPrint: A Grasshopper plug-in for voxel-based numerical simulation of concrete printing. Automation in Construction, 2021, 122: 103469 https://doi.org/10.1016/j.autcon.2020.103469
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E Ramyar, G Cusatis. Discrete fresh concrete model for simulation of ordinary, self-consolidating, and printable concrete flow. Journal of Engineering Mechanics, 2022, 148(2): 04021142 https://doi.org/10.1061/(ASCE)EM.1943-7889.0002059
Z Chang, H Zhang, M Liang, E Schlangen, B Šavija. Numerical simulation of elastic buckling in 3D concrete printing using the lattice model with geometric nonlinearity. Automation in Construction, 2022, 142: 104485 https://doi.org/10.1016/j.autcon.2022.104485
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R J M Wolfs, T A M Salet, N Roussel. Filament geometry control in extrusion-based additive manufacturing of concrete: The good, the bad and the ugly. Cement and Concrete Research, 2021, 150: 106615 https://doi.org/10.1016/j.cemconres.2021.106615
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T Pan, H Teng, H Liao, Y Jiang, C Qian, Y Wang. Effect of shaping plate apparatus on mechanical properties of 3D printed cement-based materials: Experimental and numerical studies. Cement and Concrete Research, 2022, 155: 106785 https://doi.org/10.1016/j.cemconres.2022.106785
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T PanR GuoY JiangX Ji. How do the contact surface forces affect the interlayer bond strength of 3D printed mortar? Cement and Concrete Composites, 2022, 133: 104675
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T Hanada, K Kuroda, K Takahashi. CFD geometrical optimization to improve mixing performance of axial mixer. Chemical Engineering Science, 2016, 144: 144–152 https://doi.org/10.1016/j.ces.2016.01.029
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S Jiang, Z He, Y Zhou, X Xiao, G Cao, Z Tong. Numerical simulation research on suction process of concrete pumping system based on CFD method. Powder Technology, 2022, 409: 117787 https://doi.org/10.1016/j.powtec.2022.117787
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M T Mollah, R Comminal, M P Serdeczny, B Šeta, J Spangenberg. Computational analysis of yield stress buildup and stability of deposited layers in material extrusion additive manufacturing. Additive Manufacturing, 2023, 71: 103605 https://doi.org/10.1016/j.addma.2023.103605
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M T Mollah, R Comminal, M P Serdeczny, D B Pedersen, J Spangenberg. Stability and deformations of deposited layers in material extrusion additive manufacturing. Additive Manufacturing, 2021, 46: 102193 https://doi.org/10.1016/j.addma.2021.102193
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M T Mollah, R Comminal, da Silva W R Leal, B Šeta, J Spangenberg. Computational fluid dynamics modelling and experimental analysis of reinforcement bar integration in 3D concrete printing. Cement and Concrete Research, 2023, 173: 107263 https://doi.org/10.1016/j.cemconres.2023.107263
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M T Mollah, R Comminal, M P Serdeczny, D B Pedersen, J Spangenberg. Numerical predictions of bottom layer stability in material extrusion additive manufacturing. Journal of the Minerals Metals & Materials Society, 2022, 74(3): 1096–1101 https://doi.org/10.1007/s11837-021-05035-9
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J Spangenberg, W R Leal da Silva, R Comminal, M T Mollah, T J Andersen, H Stang. Numerical simulation of multi-layer 3D concrete printing. RILEM Technical Letters, 2021, 6: 119–123 https://doi.org/10.21809/rilemtechlett.2021.142
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Spangenberg J, Leal da Silva W R. In: Buswell R, Blanco A, Cavalaro S, Kinnell P. Eds. Integrating reinforcement with 3D concrete printing: Experiments and numerical modelling. In: Proceedings of Third RILEM International Conference on Concrete and Digital Fabrication. Cham: Springer International Publishing, 2022, 379–384
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Z Liu, M Li, Y Weng, Y Qian, T N Wong, M J Tan. Modelling and parameter optimization for filament deformation in 3D cementitious material printing using support vector machine. Composites. Part B, Engineering, 2020, 193: 108018 https://doi.org/10.1016/j.compositesb.2020.108018
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Z Liu, M Li, Y W D Tay, Y Weng, T N Wong, M J Tan. Rotation nozzle and numerical simulation of mass distribution at corners in 3D cementitious material printing. Additive Manufacturing, 2020, 34: 101190 https://doi.org/10.1016/j.addma.2020.101190
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L He, W T Chow, H Li. Effects of interlayer notch and shear stress on interlayer strength of 3D printed cement paste. Additive Manufacturing, 2020, 36: 101390 https://doi.org/10.1016/j.addma.2020.101390
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M K Mohan, A V Rahul, K van Tittelboom, G de Schutter. Rheological and pumping behaviour of 3D printable cementitious materials with varying aggregate content. Cement and Concrete Research, 2021, 139: 106258 https://doi.org/10.1016/j.cemconres.2020.106258
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Y Tao, A V Rahul, M K Mohan, K van Tittelboom, Y Yuan, G de Schutter. Blending performance of helical static mixer used for twin-pipe 3D concrete printing. Cement and Concrete Composites, 2022, 134: 104741 https://doi.org/10.1016/j.cemconcomp.2022.104741
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E Lloret-Fritschi, E Quadranti, F Scotto, L Fuhrimann, T Demoulin, S Mantellato, L Unteregger, J Burger, R G Pileggi, F Gramazio, M Kohler, R J Flatt. Additive digital casting: From lab to industry. Materials, 2022, 15(10): 3468 https://doi.org/10.3390/ma15103468
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B Shantanu, J Smrati, S Manu. Criticality of binder-aggregate interaction for buildability of 3D printed concrete containing limestone calcined clay. Cement and Concrete Composites, 2023, 136: 104853 https://doi.org/10.1016/j.cemconcomp.2022.104853
Y Tao, A V Rahul, K Lesage, Y Yuan, K van Tittelboom, G de Schutter. Stiffening control of cement-based materials using accelerators in inline mixing processes: Possibilities and challenges. Cement and Concrete Composites, 2021, 119: 103972 https://doi.org/10.1016/j.cemconcomp.2021.103972
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S Hou, Z Duan, J Xiao, J Ye. A review of 3D printed concrete: Performance requirements, testing measurements and mix design. Construction and Building Materials, 2021, 273: 121745 https://doi.org/10.1016/j.conbuildmat.2020.121745
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Y Chen, Figueiredo S Chaves, Z Li, Z Chang, K Jansen, O Çopuroğlu, E Schlangen. Improving printability of limestone-calcined clay-based cementitious materials by using viscosity-modifying admixture. Cement and Concrete Research, 2020, 132: 106040 https://doi.org/10.1016/j.cemconres.2020.106040