Interfaces between layers in 3D-printed elements produced by extrusion-based material deposition were investigated on both macro- and micro-scales. On the macro-scale, compression and bend tests were performed on two 3D-printable cement-based compositions (3PCs), namely C1 and C2. The influences of binder composition and time interval between layers on layer-interface strength were critically analyzed. In the context of additive manufacturing, the optimized composition C2, containing pozzolanic additives, exhibited mechanical performance superior to that of the mixture with Portland cement as the sole binder. In particular, Mixture C2 showed a less pronounced decrease in interface tensile strength. Even for time intervals between depositions of two layers as long as 1 day the loss in corresponding flexural strength was below 25%, as compared with C2 specimens tested in the perpendicular direction. In contrast, the decrease in flexural strength measured for C1 specimens amounted to over 90% for the same set of parameters. Higher porosity at the interfaces of the printed concrete layers was identified as the cause for the lower interface strengths of C1. Microscopic observations supported the findings of the macroscopic investigations. While a pronounced recovery (“self-healing”) of the porous, discontinuous interlayers was observed with increasing age for Mixture C2, in case of C1 the filling products grown in the porous interlayer were found to be non-strengthening.

Buildability, i.e. the ability of a deposited material bulk to retain its dimmensions under increasing load, is an inherent prerequisite for formwork-free digital construction (DC). Since DC processes are relatively new, no standard methods of characterization are available yet. The paper at hand presents practice-oriented buildabilty criteria by taking various process parameters and construction costs into consideration. In doing so, direct links between laboratory buildability tests and target applications are established. A systematic basis for calculating the time interval (TI) to be followed during laboratory testing is proposed for the full-width printing (FWP) and filament printing (FP) processes. The proposed approach is validated by applying it to a high-strength, printable, fine-grained concrete. Comparative analyses of FWP and FP revealed that to test the buildability of a material for FP processes, higher velocities of the printhead should be established for laboratory tests in comparison to those needed for FWP process, providing for equal construction rates.

To enable purposeful design and implementation of automated concrete technologies, precise assessment and prediction of the complex material flow at various stages of the process chain are necessary. This paper investigates the intermediate stage of the extrusion and deposition processes in extrusion-based 3D-concrete-printing, using a numerical model based on the Particle Finite Element Method (PFEM). In PFEM, due to the Lagrangian description of motion, remeshing algorithms and the alpha shape method are used to track the free surface during large deformation scenarios. The Bingham constitutive model was used for describing the rheological behaviour of fresh concrete. This model is validated by comparing the numerically predicted layer geometries with those obtained from laboratory 3D printing experiments. Extensive parametric studies were then conducted using the numerical simulation, delineating the influence of process and material parameters on the layer geometries, the dynamic surface forces generated under the extrusion nozzle and the inter-layer interactions.

One of the major limitations of the current 3D-concrete-printing technology is incorporation of reinforcement. Furthermore, there is a need to decrease the ecological footprint of printable concrete. As a possible solution for these challenges, this paper presents a 3D-printable strain-hardening geopolymer composite (3DP-SHGC) that shows pseudo-ductile behaviour under direct tension. The developed 3DP-SHGC is composed of one-part (just-add-water) geopolymer binder made of slag (GGBFS), fly ash (FA) and solid activator. The one-part geopolymer binder eliminates the need for elevated temperature curing and handling of corrosive alkaline liquids. At first, an optimum matrix was identified by studying the effects of FA to GGBFS ratio on the rheological properties and compressive strength. Subsequently the optimum matrix was reinforced by PVA fibres to make the 3DP-SHGC, which printing performance and rheological properties were evaluated. In addition, the influences of curing temperature on the compressive, flexural and tensile performances of the printed specimens were also investigated. The results were compared with those obtained for the mould-cast specimens. The 3DP-SHGC exhibited superior flexural performance, higher tensile strength, and comparable tensile strain capacity to the mould-cast counterpart. Further, the curing temperature had influence on the mechanical properties of both 3D-printed and mould-cast SHGCs. The underlying reasons for the differences are discussed.

3D-printing with foam concrete, which is known for its distinct physical and mechanical properties, has not yet been purposefully investigated. The article at hand presents a methodological approach for the mixture design of 3D-printable foam concretes and a systematic investigation of the potential application of this type of material in digital construction. Three different foam concrete compositions with water-to-binder ratios between 0.33 and 0.36 and having densities of 1100 to 1580 kg/m³ in the fresh state were produced with a pre-foaming technique using a protein-based foaming agent. Based on the fresh-state tests, including 3D-printing as such, an optimum composition was identified and its compressive and flexural strengths were characterised. The printable foam concrete showed compressive strength above 10 MPa and low thermal conductivity, which make it suitable for 3D-printing applications, while fulfilling both load-carrying and insulating functions.