The 3 Methods for 3D Concrete Printing

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Overview of 3D Concrete Printing Methods - How Magic Happens

3D concrete printing refers to various additive manufacturing processes that construct cement-based structures in a layer-by-layer fashion directly from digital 3D model data, without the need for formwork or molds. There are currently three primary concrete printing techniques used in architectural construction applications:

  1. Layered Material ExtrusionDepositing concrete through a nozzle via pumping.
  2. Powder Bed Binder Jetting – Selectively dropping a liquid binding agent onto layers of cement powder.
  3. Robotic Slip Forming – Continuous extrusion of concrete from an actuating, robotic nozzle mold.

And while limitations exist like reinforcement integration or geometric constraints, 3D concrete printing infrastructure promises advantages in speed, customization, sustainability and affordability over conventional methods. We’ll explore the working principles, benefits and tradeoffs associated with each approach in further detail:

Table of Contents

1. Layered Extrusion Printing Method

This technique involves pumping a specially formulated cementitious “ink” through a printing nozzle mounted to a multi-axis robotic system. The print head precisely extrudes the viscous concrete mixture layer-by-layer based on a digitally programmed toolpath:

Layered Extrusion 3D Concrete Printing Method - Courtesy of World Architecture
Layered Extrusion 3D Concrete Printing Method – Courtesy of World Architecture

How It Works

The core principles behind layered extrusion printing include:

  • Digital Path Planning – Component geometry optimized for printing build process.
  • Material Delivery – Pressurized concrete composite pumped to print head nozzle.
  • Layer Fusion – Chemical bonding between deposited filaments and layers.

Specialized printable concrete mortars balance properties like pumpability, open time and build strength for improved printing behavior compared to conventional mixtures.

Extrusion Based 3D Concrete Printing Method- American Concrete Institute

Mix Design

These mortars are typically enriched with admixtures like silica fume, fly ask or polymers to achieve desired rheological properties.

This includes tailoring characteristics like:

  • Yield stress – Resists slumping between layers.
  • Viscosity – Pumpability and extrusion force.
  • Open time – Time between extrusions before plastic state is lost.

Controlling flow and stiffening rates are critical for avoiding blockages while enabling rapid overlaying of successive print layers without compromising interlayer adhesion.

Key printing parameters also heavily influence printed outcome:

  • Print speed – Faster deposition risks weaker bonding between filaments and layers.
  • Layer height – More coarse layers compromise smoothness and strength.
  • Nozzle design – Geometry impacts extrusion behavior and surface quality.

Current research focuses on developing superior concrete composites, software and hardware to expand capabilities.

Benefits

  • Doesn’t require formwork or molds.
  • Enables complex geometries impractical traditionally.
  • Simpler integration of insulation or reinforcements.
  • Minimizes material waste from substractive processes.

Limitations

  • Limited to shorter heights by stability risks.
  • Anisotropic properties from layering effects.
  • Natural concrete appearance more difficult to achieve.

Still, projects leveraging layered extrusion have demonstrated entire printed houses, buildings, bridges and other structures – unlocking architectural flexibility difficult through legacy methods.

2. Binder Jet Printing Method

Unlike layered extrusion processes, binder jetting relies on selectively joining layers of cement powder rather than bulk deposition of concrete. It shares conceptual similarities to powder bed fusion techniques used in metal 3D printing applications.

Binder Jetting 3D Concrete Printing Method - Courtesy of ExOne
Binder Jetting 3D Concrete Printing Method – Courtesy of ExOne

How It Works

The core procedural steps include:

  • Spreading measured layer of cementitious powder across build bed.
  • Print head deposits localized droplets of binding reagent.
  • Binder chemically joins powder particles upon curing.
  • Repeated to construct components layerwise.

Various portland cement blends, epoxies or inorganic polymers can serve as viable binders. And leftover surrounding powder supports overhangs and spanning layers until completion.

Benefits

Binder jetting concrete printing offers advantages like:

  • Minimizes material waste leftover powder is reusable.
  • Doesn’t require formwork or molds.
  • Enables complex geometries unsupported spans possible.

Limitations

Drawbacks of powder binding techniques involve:

  • Weaker strength limits vertical scale.
  • Rougher surface finish than extrusion flow deposition.
  • Post-processing like infiltration or hot isostatic pressing needed for full density.

So while right applications exist, dimensional capability restrictions prevent replacing conventional methods presently.

3. Robotic Slip Forming Printing Method

This alternative concrete printing technique relies on actuated robotic nozzles to incrementally extrude concrete vertically:

Slip Forming 3D Concrete Printing Method - Courtesy of Dormark
Slip Forming 3D Concrete Printing Method – Courtesy of Dormark

How It Works

The underlying printing behavior consists of:

  • Robotic nozzles directly actuating along programmed vertical paths.
  • Continuous deposition of high flowability concrete from nozzle aperture.
  • Upward advancement enables layered material accretion.

Balancing concrete rheological properties between flowability and open time is critical, so material adequately stacks without slumping over cure period.

Benefits

Some of the positives are:

  • Higher deposition rates than other printing methods.
  • Suited for large vertical structures like towers or columns.
  • Provides superior surface finish quality from molded flow.

Limitations

Drawbacks involve factors like:

  • Less geometric versatility than gantry extrusion systems.
  • Restricted to simpler vertically dominant shapes.
  • Still requires traditional formwork for more complex structures.

Contrasting Approaches

We can summarize some core differentiating capabilities between the printing techniques:

  Layered Extrusion Binder Jetting Robotic Slip Forming
Resolution Medium Highest Low
Speed Medium Slow Fastest
Post-Processing Low High Low

While all methods eliminate conventional formwork, each approach offers unique capabilities currently. Ongoing advances aim to spread adoption driving costs down and reliability up over coming years for constructing the infrastructure of tomorrow.

Hybrid Printing

Looking ahead, combining multiple printing techniques shows enormous potential for balancing weaknesses through complementary strengths. Leveraging binder jetting, extrusion and slip forming individually or in series as logical for application geometry promises to unlock greater freedom and performance than any single process alone. The future of digital construction looks bright as methods mature!

References


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