Optimization of 3D-printed cement-based composites for construction applications

Abstract

Concrete 3D printing, an innovative construction technology, enables layer-by-layer fabrication of complex structures without traditional formwork, offering increased design flexibility, reduced material waste, and lower labor costs. This technology holds significant potential for sustainable, efficient construction, addressing industry demands for faster production and more intricate architectural designs. This study aimed to optimize a 3D printed white cement paste (3DWCP) mixture through the Taguchi method by evaluating the effects of water-to-binder (w/b) ratios (0.35, 0.40, 0.45), Styrene Butadiene Rubber (SBR) at 0–12%, Polypropylene Fibers (PPF) at 0–1.5%, and red pigment at 0–1.5% on mechanical and durability properties. Mixture optimization focuses on maximizing compressive strength, flexural strength, bond strength, and ultrasonic pulse velocity while minimizing water absorption and carbonation depth. Using a small-scale gantry robot system a printing trial confirmed good workability, extrudability, and buildability, achieving stable structures up to 100 cm in height. Taguchi analysis revealed optimal combinations for enhanced performance across key properties, validating those specific ratios of SBR, PPF, and pigments improve durability and mechanical strength in 3DWCP, with applications for more durable and aesthetically 3D-printed structures in construction.