3D-printed concrete beams cut weight by half while boosting strength
Researchers have developed a method to optimize concrete structure design during 3D printing, reducing material use while maintaining structural integrity. By varying wall thickness based on stress patterns, printed concrete beams achieved up to 63% better strength-to-weight performance than conventional designs—a breakthrough that could significantly lower construction costs and environmental impact.
Originaltitel: Internal topology optimisation of 3D printed concrete structures: a method for enhanced performance and material efficiency
<p>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. 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, three different unreinforced 3DCP beams are tested in three-point bending. Results show that beams with optimised material distributions presented a higher strength-to-weight ratio, averaging 47% and 63% compared with the conventional 3D printed beam. This paper demonstrates the potential of internal topology optimisation for improving the efficiency and sustainability of 3DCP.</p>