Numerical simulation of multi-layer 3D concrete printing

Spangenberg, Jon; Silva, Wilson Ricardo Leal da; Comminal, Raphaël; Mollah, Md. Tusher; Andersen, Tine; Stang, Henrik

doi:10.21809/rilemtechlett.2021.142

Cited by 30 publications

(13 citation statements)

References 17 publications

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“…Numerical methods have been helpful in advancing our understanding of the printing process (Perrot et al, 2021;Khan and Koç, 2022). A number of studies have demonstrated the efficacy of these methods in accurately replicating experimental results (Comminal et al, 2020;Liu et al, 2020;Spangenberg et al, 2021). Liu et al attributed discrepancies between numerical and experimental results to variations in flow rate and minor changes in rheological properties post-pumping (Liu et al, 2020).…”

Section: Numerical Modelingmentioning

confidence: 99%

Developing a data-driven filament shape prediction model for 3D concrete printing

Alhussain,

Duarte,

Brown

2024

Front. Built Environ.

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With the growing global need for housing and infrastructure, 3D concrete printing (3DCP) has emerged as an innovative construction method offering several potential benefits including design flexibility, speed, and sustainability. However, enhancing the reliability of 3DCP involves managing a variety of parameters that influence various aspects of the 3D printed structure. Process parameters like nozzle velocity, nozzle diameter, nozzle height, and material flow velocity have a major impact on the structural stability and filament shape. This project aimed to develop fast and accurate data-driven models for predicting and classifying filament shape based on process parameters. A print experiment systematically varied process parameters across 144 samples. The resulting filament geometry (width, height, contact width) was measured and classified by quality. Models were trained on this data to predict filament width, contact width, filament height, and classify filaments. These models can be utilized with any buildable material - a material with a high enough yield stress to bear the weight of upper layers without significant deformation. This condition does not restrict this study’s scope as it is a prerequisite for all 3DCP applications. The models’ robustness and generalizability were confirmed through validation on literature data across various printable materials and setups. These data-driven models can aid in optimizing parameters, generating variable width filaments, and printing non-planar layers. By linking print inputs to filament outputs, this comprehensive modeling approach advances 3DCP research for more reliable and versatile concrete printing.

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Section: Numerical Modelingmentioning

confidence: 99%

Developing a data-driven filament shape prediction model for 3D concrete printing

Alhussain,

Duarte,

Brown

2024

Front. Built Environ.

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“…Note that in Eqs. (19) and (20) we made use of the expression , which holds for any invertible tensor A. The updated elastic deformation gradient and the updated elastic left Cauchy-Green deformation tensor are found from Eqs.…”

Section: Thermodynamic Consistencymentioning

confidence: 99%

“…When printing multiple layers, the shapes, the deformations, and the contact forces acting on the substrate, were previously analyzed in Refs. [15,[18][19][20][21][22]. According to the computational and experimental study in Ref.…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation of three dimensional concrete printing based on a unified fluid and solid mechanics formulation

Reinold,

Daadouch,

Meschke

2024

Front. Struct. Civ. Eng.

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Deformation control constitutes one of the main technological challenges in three dimensional (3D) concrete printing, and it presents a challenge that must be addressed to achieve a precise and reliable construction process. Model-based information of the expected deformations and stresses is required to optimize the construction process in association with the specific properties of the concrete mix. In this work, a novel thermodynamically consistent finite strain constitutive model for fresh and early-age 3D-printable concrete is proposed. The model is then used to simulate the 3D concrete printing process to assess layer shapes, deformations, forces acting on substrate layers and prognoses of possible structural collapse during the layer-by-layer buildup. The constitutive formulation is based on a multiplicative split of the deformation gradient into elastic, aging and viscoplastic parts, in combination with a hyperelastic potential and considering evolving material properties to account for structural buildup or aging. One advantage of this model is the stress-update-scheme, which is similar to that of small strain plasticity and therefore enables an efficient integration with existing material routines. The constitutive model uses the particle finite element method, which serves as the simulation framework, allowing for modeling of the evolving free surfaces during the extrusion process. Computational analyses of three printed layers are used to create deformation plots, which can then be used to control the deformations during 3D concrete printing. This study offers further investigations, on the structural level, focusing on the potential structural collapse of a 3D printed concrete wall. The capability of the proposed model to simulate 3D concrete printing processes across the scales—from a few printed layers to the scale of the whole printed structure—in a unified fashion with one constitutive formulation, is demonstrated.

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“…In complement to the physical printing, CFD modelling is able to reproduce the extrusion-deposition of the printable concrete and investigate some specific constraints to the physical print [19][20][21][22]. The angular toolpath planning in 3DCP is in its infancy.…”

Section: Introductionmentioning

confidence: 99%

Numerical modelling of planned corner deposition in 3D concrete printing

El Abbaoui,

Al Korachi,

Mollah

et al. 2023

Archives of Materials Science and Engineering

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Analysis of different path planning strategies and the effects of changing printhead direction in the geometrical conformity and the process precision around 90 corner in order to enable a simple and cost-effective way of facilitating the determination of an optimal printing mode for fast and accurate print corners in 3D concrete printing.The material flow is characterized by a viscoplastic Bingham fluid. The printhead moves according to a prescribed speed to print the trajectory. The model solves the Navier-Stokes equations and uses the volume of fluid (VOF) technique. The acceleration steps and jerk (j) carry out the direction change. A smoothing factor is provided to smooth the toolpath. Several simulations were performed by varying the smoothing factor and jerk.Overfilling at the sharp corner was found when the printhead velocity was kept constant while extruding mortar at a fixed extrusion velocity; however, proportional extrusion velocity with the printhead motion has improved the quality of the corner. Otherwise, a slight improvement in the corner shape related to applying a jerk was found.The Computational Fluid Dynamics (CFD) model could take an important amount of computing time to solve the problem; however, it serves as an efficient tool for accelerating different costly and time-consuming path planning processes for 3D concrete printing. Smaller angles and tilted printhead positions should be numerically and experimentally investigated in future research.The developed CFD model is suited for executing parametric studies in parallel to determine the appropriate printing motion strategy for each trajectory with corners.Computational Fluid Dynamics investigation of the path planning strategy for printing trajectory with a right-angle corner in 3D concrete printing.

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Numerical simulation of multi-layer 3D concrete printing

Cited by 30 publications

References 17 publications

Developing a data-driven filament shape prediction model for 3D concrete printing

Developing a data-driven filament shape prediction model for 3D concrete printing

Numerical simulation of three dimensional concrete printing based on a unified fluid and solid mechanics formulation

Numerical modelling of planned corner deposition in 3D concrete printing

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