Optimising 3D Printed Concrete Structures

Abstract

Additive manufacturing and 3D printing are rapidly developing digital fabrication techniques. After the first steps in printing of metals and plastics have been made, research from various groups around the world is now also focusing on printing in concrete and moving to larger scales. Using this technique it will be possible to create customised concrete designs in one go at low costs and high construction speeds. Additionally, this new technology will provide opportunities to create more efficient structures. Structures can already be optimised in the early stages of the design for weight and structural performance, but the resulting optimised structures are often difficult to manufacture due to their shape. Additive manufacturing can be the key to make this possible without high costs for moulds and labour.

This thesis will present a novel methodology to include material and manufacturing constraints of 3D printed concrete in the optimisation process. The study examines the possibility to optimise concrete structures in the design phase. In order to save material and thus create more sustainable and more cost efficient structures, a topology optimisation tool has been created specifically for 3D printed concrete. Traditional topology optimisation methods consider isotropic and linear elastic material and will not necessarily produce realisable and reliable optimised structures. In the algorithm presented constraints of the printing process and material properties from physical testing of this layered material are both considered in the optimisation. By adopting this methodology more realistic and feasible optimal concrete structures can be designed.