Internal topology optimisation of 3D printed concrete structures : A method for enhanced performance and material efficiency

• Extrusion-based 3D concrete printing (3DCP) is a promising technique for fabricating complex concrete elements without formwork, offering advantages like cost reduction and enhanced design flexibility by decoupling manufacturing costs from part complexity. By placing material only where structurally needed, 3DCP can lead to significant material savings, potentially reducing the environmental footprint of the construction industry. However, this extended formal freedom is still constrained by the fabrication process and material properties. This paper presents a novel method for applying topology optimisation internally i.e., preserving the external boundaries of the concrete element while reducing material use and weight. This method adapts the extrusion thickness along the part according to the expected stresses, reducing the material use while enhancing structural performance. To validate this method, the mechanical behaviour of three different unreinforced 3DCP beams is tested in three-point bending. Results show that beams with optimised material distributions presented a higher strength-to-weight ratio than the conventional 3D printed beam. An important advantage of the proposed method is that it can be easily implemented in existing 3DCP systems without specialised equipment. This paper demonstrates the potential of internal topology optimisation for improving the efficiency and sustainability of 3DCP.

Ämnesord

TEKNIK OCH TEKNOLOGIER  -- Samhällsbyggnadsteknik -- Husbyggnad (hsv//swe)

ENGINEERING AND TECHNOLOGY  -- Civil Engineering -- Building Technologies (hsv//eng)

TEKNIK OCH TEKNOLOGIER  -- Samhällsbyggnadsteknik -- Arkitekturteknik (hsv//swe)

ENGINEERING AND TECHNOLOGY  -- Civil Engineering -- Architectural Engineering (hsv//eng)

Nyckelord

3D concrete printing

additive manufacturing

optimised concrete

robotic fabrication

design-to-manufacture workflow

Architectural Technology

Arkitekturteknik

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