Digital design computing and modelling for 3-D concrete printing

Abstract A novel computational framework of 3D concrete printing (3DCP) process is proposed in this paper to capture layer-by-layer buildability and failure modes of complex triply periodic minimal surface (TPMS) Gyroid and Primitive blocks. The proposed computational framework is conducted using toolpath dataset converted from Gcode as input source, which is extracted from virtual model created by 3D printing slicing software. The newly developed computational framework is validated by experimental outcomes of a hollow cylinder printed using nano-clay cement mix. The framework can predict various failure modes of the printed hollow cylinder, and its outcomes agree well with the experimental results. The 3DCP process of the TPMS blocks is then modelled by using the selected printing material from the experiment. The Gyroid structure is demonstrated numerically to have a lower buildability in comparison with the Primitive counterpart. Further, parametric and sensitivity analyses are conducted to reveal the effects of printing speed on buildability and its vertical deformation in the concrete printing process.

[1]  Ted Belytschko,et al.  Cracking particles: a simplified meshfree method for arbitrary evolving cracks , 2004 .

[2]  Mary Frecker,et al.  Topology Optimization Software for Additive Manufacturing: A Review of Current Capabilities and a Real-World Example , 2016, DAC 2016.

[3]  Chenxi Peng,et al.  Bioinspired functionally graded gyroid sandwich panel subjected to impulsive loadings , 2020 .

[4]  Nicolas Roussel,et al.  Rheological requirements for printable concretes , 2018, Cement and Concrete Research.

[5]  M. Tan,et al.  Rotation nozzle and numerical simulation of mass distribution at corners in 3D cementitious material printing , 2020 .

[6]  E. A. Flores-Johnson,et al.  A numerical study of bioinspired nacre-like composite plates under blast loading , 2015 .

[7]  Rjm Rob Wolfs,et al.  Numerical simulations of concrete processing: From standard formative casting to additive manufacturing , 2020, Cement and Concrete Research.

[8]  Jay G. Sanjayan,et al.  Steel fibres reinforced 3D printed concrete: Influence of fibre sizes on mechanical performance , 2020 .

[9]  Freek Bos,et al.  Early age mechanical behaviour of 3D printed concrete: Numerical modelling and experimental testing , 2018 .

[10]  Yongsheng Ma,et al.  Path Planning Strategies to Optimize Accuracy, Quality, Build Time and Material Use in Additive Manufacturing: A Review , 2020, Micromachines.

[11]  Markus J Buehler,et al.  Three-Dimensional-Printing of Bio-Inspired Composites. , 2016, Journal of biomechanical engineering.

[12]  M. Bendsøe.  Optimal shape design as a material distribution problem , 1989 .

[13]  Rjm Rob Wolfs,et al.  Structural failure during extrusion-based 3D printing processes , 2019, The International Journal of Advanced Manufacturing Technology.

[14]  Asj Akke Suiker,et al.  Mechanical performance of wall structures in 3D printing processes: Theory, design tools and experiments , 2018 .

[15]  V. Mechtcherine,et al.  Extrusion Process Simulation and Layer Shape Prediction during 3D-Concrete-Printing Using The Particle Finite Element Method , 2020, Automation in Construction.

[16]  Yi Min Xie,et al.  Topology optimization of 3D continuum structures under geometric self-supporting constraint , 2020 .

[17]  A. Suiker,et al.  Elastic buckling and plastic collapse during 3D concrete printing , 2020 .

[18]  Jan Olek,et al.  Additive Manufacturing and Performance of Architectured Cement‐Based Materials , 2018, Advanced materials.

[19]  Nicolas Roussel,et al.  Digital Concrete: Opportunities and Challenges , 2016 .

[20]  Lex Reiter,et al.  Setting on demand for digital concrete – Principles, measurements, chemistry, validation , 2020 .

[21]  G. Lu,et al.  Influences of Printing Pattern on Mechanical Performance of Three-Dimensional-Printed Fiber-Reinforced Concrete. , 2020, 3D printing and additive manufacturing.

[22]  A. Mateus,et al.  Experimental Study on 3D Printing of Concrete with Overhangs , 2020 .

[23]  T. Belytschko,et al.  A three dimensional large deformation meshfree method for arbitrary evolving cracks , 2007 .

[24]  S. Rudykh,et al.  Mechanical behavior of bio-inspired nacre-like composites: A hybrid multiscale modeling approach , 2020, Composite Structures.

[25]  Jacques Kruger,et al.  3D concrete printing: A lower bound analytical model for buildability performance quantification , 2019, Automation in Construction.

[26]  Yi Min Xie,et al.  Evolutionary structural optimisation (ESO) using a bidirectional algorithm , 1998 .

[27]  Ming Jen Tan,et al.  Mechanical properties and deformation behaviour of early age concrete in the context of digital construction , 2019, Composites Part B: Engineering.

[28]  T.A.M. Salet,et al.  Triaxial compression testing on early age concrete for numerical analysis of 3D concrete printing , 2019, Cement and Concrete Composites.

[29]  Celeste Viljoen,et al.  3D concrete printer parameter optimisation for high rate digital construction avoiding plastic collapse , 2020 .

[30]  H. Nguyen-Xuan,et al.  Bioinspired cellular cementitious structures for prefabricated construction: Hybrid design & performance evaluations , 2020 .

[31]  Deepak Rai,et al.  Bio-inspired optimization techniques: a critical comparative study , 2013, SOEN.

[32]  Jacques Kruger,et al.  An ab initio approach for thixotropy characterisation of (nanoparticle-infused) 3D printable concrete , 2019, Construction and Building Materials.

[33]  H. Nguyen-Xuan,et al.  A simple and robust three-dimensional cracking-particle method without enrichment , 2010 .