Use of polymer concrete for large-scale 3D printing

Abstract

Purpose This paper aims to focus on the evaluation of a polymer concrete as a three-dimensional (3D) printing material. An associated company has developed plastic concrete made from reused unrecyclable plastic waste. Its intended use is as a construction material. Design/methodology/approach The concrete mix, called PolyBet, composed of polypropylene and glass sand, is printed by the fused deposition modelling process. The process of material and parameter selection is described. The mechanical properties of the filled material were compared to its cast state. Samples were made from castings and two different orientations of 3D-printed parts. Three-point flex tests were carried out, and the area of the break was examined. Computed tomography of the samples was carried out. Findings The influence of the 3D printing process on the material was evaluated. The mechanical performance of the longitudinal samples was close to the cast state. There was a difference in the failure mode between the states, with cast parts exhibiting a tougher behaviour, with fractures propagating in a stair-like manner. The 3D-printed samples exhibited high degrees of porosity. Originality/value The results suggest that the novel material is a good fit for 3D printing, with little to no degradation caused by the process. Layer adhesion was shown to be excellent, with negligible effect on the finished part for the longitudinal orientation. That means, if large-scale testing of buildability is successful, the material is a good fit for additive manufacturing of building components and other large-scale structures.

A critical review of 3D printing and digital manufacturing in construction engineering

“…A polymer concrete-based large-scale printing for construction was studied and the influence of process parameters on the material was evaluated (Krčma et al , 2021).…”

“…It was found excellent layer adhesion with negligible effect on the finished part for the longitudinal orientation. It indicates, if the large-scale buildability is successful, the material is very suitable for 3D printed building components and other large-scale building structures (Krčma et al , 2021).…”

The Aging of Polymers under Electromagnetic Radiation

“…Bedi et al [ 86 ] note that although more costly than conventional concrete, polymer concrete is reputed to possess an enhanced microstructure, which offers it better durability. Krčma et al [ 87 ] and Furet et al [ 88 ] explain that to create 3D polymer concrete, aggregates, polymer resin, and fillers are mixed with a substituted cement binder. The resulting polymer concrete can thus be used in 3D printing, wherein the stability of the shape is a vital feature.…”

“… There is a need for further research to determine whether 3D polymers have health detriments [ 86 ] Bedi et al Reviewing some properties of polymer concrete Secondary research methodology based on a literature review Polymer concretes’ characteristics differ greatly based on their conditions of preparation. Precast polymer concrete is being used to manufacture various products such as acid tanks, manholes, drains, and highway median barriers [ 87 ] Krčma et al Use of polymer concrete for large-scale 3D printing The quantitative study used the deposition modeling process and computed tomography of polymer samples The 3D-printed samples showed high levels of porosity. The new polymer material is useful in 3D printing, with negligible to no degradation resulting from the process [ 88 ] Furet et al 3D printing for construction based on a complex wall of polymer-foam and concrete An experimental study was conducted Polymer concretes are mixed with fillers, resins, and aggregates to provide a substitute binder for cement in additive manufacturing.…”

Polymer/Carbon Fiber Co-modification: Dynamic Compressive Mechanical Properties of Carbon Fiber Modified Polymer Reinforced Concrete

“…Polymer reinforced concrete is a composite formed by mixing cement and aggregate with organic polymer materials that are dispersed or can be dispersed in water (Krčma et al 2021;Hammodat 2021). The addition of polymer in ordinary concrete may improve many properties of concrete, e.g., deformation capacity, bond performance, waterproof performance and durability (Ferdous et al 2020;Sabău et al 2020).…”