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Internal topology optimisation of 3D printed concrete structures: a method for enhanced performance and material efficiency
KTH, School of Architecture and the Built Environment (ABE), Civil and Architectural Engineering, Concrete Structures. KTH, School of Architecture and the Built Environment (ABE), Architecture, Architectural Technologies.ORCID iD: 0000-0002-0641-0567
KTH, School of Architecture and the Built Environment (ABE), Civil and Architectural Engineering, Concrete Structures.ORCID iD: 0000-0001-8375-581X
KTH, School of Architecture and the Built Environment (ABE), Architecture, Architectural Technologies.ORCID iD: 0000-0002-2313-8809
KTH, School of Architecture and the Built Environment (ABE), Civil and Architectural Engineering, Structural Engineering and Bridges. KTH, School of Architecture and the Built Environment (ABE), Civil and Architectural Engineering, Concrete Structures.ORCID iD: 0000-0002-1526-9331
2024 (English)In: Virtual and Physical Prototyping, ISSN 1745-2759, E-ISSN 1745-2767, Vol. 19, no 1Article in journal (Refereed) Published
Abstract [en]

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.

Place, publisher, year, edition, pages
Informa UK Limited , 2024. Vol. 19, no 1
Keywords [en]
3D concrete printing, additive manufacturing, optimised concrete, robotic fabrication
National Category
Building Technologies Architectural Engineering
Research subject
Civil and Architectural Engineering, Concrete Structures; Civil and Architectural Engineering, Building Technology
Identifiers
URN: urn:nbn:se:kth:diva-346459DOI: 10.1080/17452759.2024.2346290ISI: 001216470600001Scopus ID: 2-s2.0-85192551840OAI: oai:DiVA.org:kth-346459DiVA, id: diva2:1858094
Funder
Svenska Byggbranschens Utvecklingsfond (SBUF), 13791Vinnova, 2020-00257
Note

QC 20240515

This project has received support from Hesselmanska Foundation, the Development Fund of the Swedish Construction Industry (SBUF) 13791, and the strategic innovation program Smart Built Environment (2020-00257), which is part of the strategic innovation areas initiative funded by Vinnova — the Swedish Innovation Agency, Formas — a Swedish Research Council for Sustainable Development and the Swedish Energy Agency. Printable material for 3DCP experiments was supplied by Sika (Sika Sverige AB).

Available from: 2024-05-15 Created: 2024-05-15 Last updated: 2025-03-17Bibliographically approved

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Hernández Vargas, JoséSjölander, AndreasWesterlind, HelenaSilfwerbrand, Johan

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