Details
| Original language | English |
|---|---|
| Article number | 115050 |
| Journal | Materials and design |
| Volume | 260 |
| Early online date | 1 Nov 2025 |
| Publication status | Published - Dec 2025 |
Abstract
Advancing additive manufacturing in construction (AMC) requires a clear understanding of feasible geometries and process capabilities for each technology. This paper maps the measurable design space of Shotcrete 3D Printing (SC3DP) and proposes a systematic overview linking geometric possibilities and process parameters. Two complementary experimental approaches are combined to provide a comprehensive framework for evaluating SC3DP, bridging the gap between practical implementation and fundamental insights into material-process interaction. The first set of experiments investigates path planning parameters and print strategies. Systematic evaluation evidences high dimensional accuracy, reliable radii from approx. 120 mm and printable overhangs up to 30° inclination. Additionally, practical guidelines are articulated. The second set of experiments focuses on material-process interaction by quantifying how traverse speed, concrete volume flow, nozzle-to-strand distance and air volume flow influence layer geometry. Measured outcomes indicate achievable layer widths of 75–180 mm and heights of 8–50 mm. The correlations among parameters and outputs are discussed to delineate the geometric possibilities. Together, these results define a reproducible method to chart SC3DP capabilities and deliver an overview of geometric possibilities. The framework supports fabrication-aware design, parameter selection and scaling, positioning SC3DP as a versatile AMC process for structurally relevant, performance-oriented applications.
Keywords
- Additive manufacturing in construction, Concrete printing, Geometric freedom, Material-process interaction, Printing accuracy, Process control, Shotcrete 3D printing
ASJC Scopus subject areas
- Materials Science(all)
- General Materials Science
- Engineering(all)
- Mechanics of Materials
- Engineering(all)
- Mechanical Engineering
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In: Materials and design, Vol. 260, 115050, 12.2025.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Investigation on process guidelines and geometric capabilities for robust Shotcrete 3D Printing
AU - Dörrie, Robin
AU - Lachmayer, Lukas
AU - Baghdadi, Abtin
AU - David, Martin
AU - Dröder, Klaus
AU - Raatz, Annika
AU - Kloft, Harald
N1 - Publisher Copyright: © 2025 The Author(s).
PY - 2025/12
Y1 - 2025/12
N2 - Advancing additive manufacturing in construction (AMC) requires a clear understanding of feasible geometries and process capabilities for each technology. This paper maps the measurable design space of Shotcrete 3D Printing (SC3DP) and proposes a systematic overview linking geometric possibilities and process parameters. Two complementary experimental approaches are combined to provide a comprehensive framework for evaluating SC3DP, bridging the gap between practical implementation and fundamental insights into material-process interaction. The first set of experiments investigates path planning parameters and print strategies. Systematic evaluation evidences high dimensional accuracy, reliable radii from approx. 120 mm and printable overhangs up to 30° inclination. Additionally, practical guidelines are articulated. The second set of experiments focuses on material-process interaction by quantifying how traverse speed, concrete volume flow, nozzle-to-strand distance and air volume flow influence layer geometry. Measured outcomes indicate achievable layer widths of 75–180 mm and heights of 8–50 mm. The correlations among parameters and outputs are discussed to delineate the geometric possibilities. Together, these results define a reproducible method to chart SC3DP capabilities and deliver an overview of geometric possibilities. The framework supports fabrication-aware design, parameter selection and scaling, positioning SC3DP as a versatile AMC process for structurally relevant, performance-oriented applications.
AB - Advancing additive manufacturing in construction (AMC) requires a clear understanding of feasible geometries and process capabilities for each technology. This paper maps the measurable design space of Shotcrete 3D Printing (SC3DP) and proposes a systematic overview linking geometric possibilities and process parameters. Two complementary experimental approaches are combined to provide a comprehensive framework for evaluating SC3DP, bridging the gap between practical implementation and fundamental insights into material-process interaction. The first set of experiments investigates path planning parameters and print strategies. Systematic evaluation evidences high dimensional accuracy, reliable radii from approx. 120 mm and printable overhangs up to 30° inclination. Additionally, practical guidelines are articulated. The second set of experiments focuses on material-process interaction by quantifying how traverse speed, concrete volume flow, nozzle-to-strand distance and air volume flow influence layer geometry. Measured outcomes indicate achievable layer widths of 75–180 mm and heights of 8–50 mm. The correlations among parameters and outputs are discussed to delineate the geometric possibilities. Together, these results define a reproducible method to chart SC3DP capabilities and deliver an overview of geometric possibilities. The framework supports fabrication-aware design, parameter selection and scaling, positioning SC3DP as a versatile AMC process for structurally relevant, performance-oriented applications.
KW - Additive manufacturing in construction
KW - Concrete printing
KW - Geometric freedom
KW - Material-process interaction
KW - Printing accuracy
KW - Process control
KW - Shotcrete 3D printing
UR - http://www.scopus.com/inward/record.url?scp=105021058830&partnerID=8YFLogxK
U2 - 10.1016/j.matdes.2025.115050
DO - 10.1016/j.matdes.2025.115050
M3 - Article
AN - SCOPUS:105021058830
VL - 260
JO - Materials and design
JF - Materials and design
SN - 0264-1275
M1 - 115050
ER -