Design & Development of a Concrete 3D Printer

Abstract

This research focuses on designing and developing a concrete 3D printer which uses the Fused Deposition Modeling (FDM) technology. The primary objective of this thesis is to introduce 3D Concrete Printing (3DCP) technology in Pakistan to address the housing challenges and providing cost-effective efficient construction solutions. This research aims to contribute to the construction industry by proposing a conceptual design, fabricating a 3D printer, investigating different concrete mixes, evaluating performance of the developed printer, and employing recycled and agro-based materials to the mixture to make it sustainable. This technology holds the potential to revolutionize the construction industry, reduce labor costs and injuries, and use raw materials efficiently which will positively impact the region’s economy. The study also explores the intricate relationship between different concrete additives and their influence on the mechanical strength of 3D printable concrete (3DPC). By emphasizing the importance of balancing printability, strength, and evaluating specific additives such as Fly Ash, Silica Fume, Rice Husk Ash, Crushed Recycled Concrete, and Crushed Recycled glass, this research provides valuable insights about the basis on which a material mixture must be designed for 3D printing (3DP). Also, by employing superplasticizer and viscosity modifying admixture, the research comprehensively analyzes the flow properties of fresh 3DPC and the strength performance of water-cured samples at day 7 and 28. The significance of early-stage strength development and sustainability considerations empowers this research to contributes to the existing discourse surrounding 3DCP technology, paving the way for an additive-enriched formulation that harmonizes printability, structural performance, and environmental responsibility