Large-scale 3D printing of ultra-high performance concrete – a new processing route for architects and builders

Abstract

International audienceIn the present paper a new additive manufacturing processing route is introduced for ultra-high performance concrete. Interdisciplinary work involving materials science, computation, robotics, architecture and design resulted in the development of an innovative way of 3D printing cementitious materials. The 3D printing process involved is based on a FDM-like technique, in the sense that a material is deposited layer by layer through an extrusion printhead mounted on a 6-axis robotic arm. The mechanical properties of 3D printed materials are assessed. The proposed technology succeeds in solving many of the problems that can be found in the literature. Most notably, this process allows the production of 3D large-scale complex geometries, without the use of temporary supports, as opposed to 2.5D examples found in the literature for concrete 3D printing. Architectural cases of application are used as examples in order to demonstrate the potentialities of the technology. Two structural elements were produced and constitute some of the largest 3D printed concrete parts available until now. Multi-functionality was enabled for both structural elements by taking advantage of the complex geometry which can be achieved using our technology for large-scale additive manufacturing

Current Progress of 3D Concrete Printing Technologies

“…Increasing architectural freedom, which would enable more sophisticated designs for structural and aesthetic purposes; and 8. Enabling potential of multifunctionality for structural/architectural elements by taking advantege of the complex geometry [9,10].…”

“…Gosselin et al [10] reported the following drawbacks for the CC technology: (1) this technology is limited to vertical extrusion, hence yielding 2.5D topologies (vertical extension of a planar shape), (2) the initial formwork and trowel system can be rather complex to implement for production, depending on the size and shape of the object being printed, and (3) the interrupted sequential casting of concrete within the formwork due to hydrostatic pressure and weak mechanical properties of the extruded concrete may result in weakened interfacial zones between the layers.…”

“…Gosselin et al [10] reported the following drawbacks in regards to the Concrete Printing technology: (1) the trade-off necessary for maintaining its dimensional accuracy makes the process quite slow with regards to the envisioned industrial application, (2) although the technology initially aimed at the generation of 3D topologies rather than 2.5D, the use of second material to support overhangs reduces the efficiency and flexibility of the process while increasing its material cost, and (3) dimensions and possibilities in terms of shape-design are limited by the dimensions of the printing frame.…”

“…Based upon an understanding of the limitations identified in the aforementioned CC and Concrete Printing technologies, a new technology has been introduced by a research team in France for large-scale 3DCP using ultra-high performance concrete (UHPC) [10]. The developed technology uses the extrusionbased technique to deposit UHPC layer by layer through an extrusion print head mounted on a 6-axes robotic arm.…”

The cost calculation method of construction 3D printing aligned with internet of things

“…They proved that the material comes from the construction waste, cement, organic binder, and fibers. However, Gosselin et al [12] believed that the overall material cost of C3DP was higher than the cost of traditional construction material due to the special properties of concrete and other materials required by C3DP. Nathalie et al considered that there was not too much difference between the cost of material and labor in C3DP and the cost of traditional in-situ reinforced concrete [13].…”