Mechanical performance of wall structures in 3D printing processes: Theory, design tools and experiments

Suiker, A.S.J.

doi:10.1016/j.ijmecsci.2018.01.010

Cited by 213 publications

(170 citation statements)

References 15 publications

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“…In order to validate the accuracy of the parametric 3D printing model and support the implementation of the design formulas and graphs presented in [21] in engineering practice, it is useful to compare results of this model to those obtained by dedicated finite element method (FEM) analyses and supplementary 3D printing experiments. A design parameter that deserves special attention in this comparison study is the material curing rate, or, analogously, the printing velocity, since its optimisation straightforwardly leads to a reduction in printing time, and thus to a decrease of the manufacturing costs.…”

Section: Elastic Bucklingmentioning

confidence: 99%

“…The experimental validation is directed towards free walls manufactured by 3D concrete printing, whereby the effect of the material curing rate on the failure behaviour of the wall is explored by considering walls of various widths. The validation study includes the linear and exponentially decaying, time-dependent curing processes analysed in [21], and suggests the application of a quadratic curing function if the curing process under a relatively long printing time is accelerated by thermal heating of the 3D printing facility.…”

Section: Elastic Bucklingmentioning

confidence: 99%

“…Recently, Suiker [21] developed a mechanistic parametric model that can be used for the prediction of structural failure of straight, free-standing walls generated during E3DP processes. The model focuses on the competition between elastic buckling and plastic collapse (see Fig.…”

Section: Introductionmentioning

confidence: 99%

“…The elastic buckling mechanism reflects failure caused by a loss of geometrical stability, while plastic collapse is characterised by the maximum stress (at the bottom of the wall) reaching the material yield strength. The parametric model in [21] reveals the sensitivity of these failure mechanisms to the actual printing process parameters, which are the curing properties of the printing material, the printing velocity, the geometrical features of the printed object, the heterogeneous strength and stiffness characteristics of the object, the non-uniform dead weight loading and the presence of imperfections. It is demonstrated that the relatively large number of parameters characterising the 3D printing process can be reduced to five unique, dimensionless (time and length scale) parameters, with three parameters defining elastic buckling and two parameters representing plastic collapse.…”

Section: Introductionmentioning

confidence: 99%

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Structural failure during extrusion-based 3D printing processes

Wolfs

Suiker

2019

Int J Adv Manuf Technol

145

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This contribution studies failure by elastic buckling and plastic collapse of wall structures during extrusion-based 3D printing processes. Results obtained from the parametric 3D printing model recently developed by Suiker (Int J Mech Sci, 137: 145-170, 2018), among which closed-form expressions useful for engineering practice, are validated against results of dedicated FEM simulations and 3D concrete printing experiments. In the comparison with the FEM simulations, various types of wall structures are considered, which are subjected to linear and exponentially decaying curing processes at different curing rates. For almost all cases considered, the critical wall buckling length computed by the parametric model turns out to be in excellent agreement with the result from the FEM simulations. Some differences may occur for the particular case of a straight wall clamped along its vertical edges and subjected to a relatively high curing rate, which can be ascribed to the approximate form of the horizontal buckling shape used in the parametric model. The buckling responses computed by the two models for a wall structure with imperfections of different wavelengths under increasing deflection correctly approaches the corresponding bifurcation buckling length. Further, under a specific change of the material properties, the parametric model and the FEM model predict a similar transition in failure mechanism, from elastic buckling to plastic collapse. The experimental validation of the parametric model is directed towards walls manufactured by 3D concrete printing, whereby the effect of the material curing rate on the failure behaviour of the wall is explored by studying walls of various widths. At a relatively low curing rate, the experimental buckling load is well described when the parametric model uses a linear curing function. However, the experimental results suggest the extension of the linear curing function with a quadratic term if the curing process under a relatively long printing time is accelerated by thermal heating of the 3D printing facility. In conclusion, the present validation study confirms that the parametric model provides a useful research and design tool for the prediction of structural failure during extrusion-based 3D printing. The model can be applied to quickly and systematically explore the influence of the individual printing process parameters on the failure response of 3D-printed walls, which can be translated to directives regarding the optimisation of material usage and printing time.

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Section: Elastic Bucklingmentioning

confidence: 99%

Section: Elastic Bucklingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Structural failure during extrusion-based 3D printing processes

Wolfs

Suiker

2019

Int J Adv Manuf Technol

145

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“…Secondly, these models can offer the potential to further tune the existing structural optimisation strategies and help to solve key challenges in the future.To this end, different analytical models already exist and have been developed for concrete printing applications (mainly layered extrusion DFC processes). For example, Suiker[118] proposed a mechanistic model to analyse and optimise the mechanical performance of straight unreinforced wall structures in 3D printing processes. The model investigates the influence of the printing speed, curing of the material, and geometrical features on failure mechanisms such as elastic buckling and plastic collapse.…”

mentioning

confidence: 99%

Opportunities and challenges for structural engineering of digitally fabricated concrete

Menna

Mata‐Falcón

Bos

et al. 2020

Cement and Concrete Research

155

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An elastic‐inelastic model and embedded bounce‐back control for layered printing with cementitious materials

Wijaya

Kreiger

Masud

2022

Numerical Meth Engineering

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This paper presents a finite‐deformation model for extrusion‐based layered printing with cementitious materials. The evolution of mechanical properties as the printed material cures and stiffens results in nonphysical reduction in the magnitude of elastic strains when standard constitutive models are employed. This elastic recovery of the printing induced deformation contradicts the experimentally observed behavior of the printed cementitious materials that harden at a nearly‐frozen deformed state. A thermodynamically motivated constraint on the evolution of elastic strains is imposed on the constitutive model to remedy the nonphysical bounce‐back effect. An algorithm that is based on a strain‐projection technique for the elastic part of deformation is developed that complements the inelastic response given by the Drucker–Prager model. It is then embedded in a finite strain finite element framework for the modeling and simulation of cure hardening and inelastic response of the early age cementitious materials. A ghost mesh method is proposed for continuous layer‐wise printing of the material without the need for intermittent mesh generation technique or adaptive remeshing methods. The model is validated via comparison with experimental data and representative test cases are presented that investigate the mathematical and computational attributes of the proposed model.

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Mechanical performance of wall structures in 3D printing processes: Theory, design tools and experiments

Cited by 213 publications

References 15 publications

Structural failure during extrusion-based 3D printing processes

Structural failure during extrusion-based 3D printing processes

Opportunities and challenges for structural engineering of digitally fabricated concrete

An elastic‐inelastic model and embedded bounce‐back control for layered printing with cementitious materials

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