A 3D Printing Method of Cement-Based FGM Composites Containing Granulated Cork, Polypropylene Fibres, and a Polyethylene Net Interlayer

Abstract

The increasing popularity of additive manufacturing technologies in the prototyping and building industry requires the application of novel, improved composite materials. In this paper, we propose the use of a novel 3D printing cement-based composite material with natural, granulated cork, and additional reinforcement using a continuous polyethylene interlayer net combined with polypropylene fibre reinforcement. Our assessment of different physical and mechanical properties of the used materials during the 3D printing process and after curing verified the applicability of the new composite. The composite exhibited orthotropic properties, and the compressive toughness in the direction of layer stacking was lower than that perpendicular to it, by 29.8% without net reinforcement, 42.6% with net reinforcement, and 42.9% with net reinforcement and an additional freeze–thaw test. The use of the polymer net as a continuous reinforcement led to decreased compressive toughness, lowering it on average by 38.5% for the stacking direction and 23.8% perpendicular to the stacking direction. However, the net reinforcement additionally lowered slumping and elephant’s foot effects. Moreover, the net reinforcement added residual strength, which allowed for the continuous use of the composite material after the failure of the brittle material. Data obtained during the process can be used for further development and improvement of 3D-printable building materials.

Numerical Evaluation on Thermal Performance of 3D Printed Concrete Walls: The Effects of Lattice Type, Filament Width and Granular Filling Material

“…This is the case for recycled sand, which has growing applications in construction due to sustainability concerns. Mohammad et al [56] developed a high-performance lightweight concrete for 3D printing, while Pietras et al [57] developed a novel 3D printing cement-based composite material with granulated cork. The application of such materials improves the thermal performance of 3DPC envelopes.…”

A Novel Approach for 3D Printing Fiber-Reinforced Mortars

“…On the other hand, in order to ensure the ductility of the 3D-printed structures, as well as to fulfill certain conditions referring to the mechanical characteristics, various reinforcement methods have been proposed and analyzed by researchers [ 31 ]. Based on the literature review, some of the most investigated reinforcements that are suitable for 3D-printed mortars include polymer fibers (polypropylene, glass, and carbon), metallic fibers, steel bars (placed before or during the printing process), polymer or steel meshes (placed before or during the printing process), nails or short rebars (placed perpendicular to at least two consecutive layers of the printed material), U-shaped nails (placed in a specific pattern on each layer of material), tensioned strands (similar to reinforced concrete post-tensioned members), and steel cables (capable of following the printing path) [ 32 , 33 , 34 , 35 , 36 , 37 , 38 , 39 , 40 , 41 , 42 , 43 , 44 , 45 , 46 , 47 , 48 , 49 , 50 , 51 ].…”