journal article·2022-02-01Open access

Additive Manufacturing of Sustainable Construction Materials and Form-finding Structures: A Review on Recent Progresses

Junli Liu, Vuong Nguyen-Van, Biranchi Panda, Kate Fox, Anton du Plessis, Phuong Tran

Abstract

Recently, there has been an increasing interest on the sustainability advantage of 3D concrete printing (3DCP), where the original cement-based mixtures used for printing could be replaced or incorporated with environmental-friendly materials. The development in digital modeling and design tools also creates a new realm of form-finding architecture for 3DCP, which is based on topological optimization of volumetric mass and physical performance. This review provides a perspective of using different green cementitious materials, applications of structural optimization, and modularization methods for realizing sustainable construction with additive manufacturing. The fresh and hardened mechanical properties of various sustainable materials for extrusion-based 3D printing are presented, followed by discussions on different topology optimization techniques. The current state of global research and industrial applications in 3DCP, along with the development of sustainable construction materials, is also summarized. Finally, research and practical gaps identified in this review lead to several recommendations on material developments, digital design tool's prospects for 3DCP to achieve the sustainability goal.
Source: openalex_inverted_index · Quality: baseline

Research context

OpenAlex topics: Innovations in Concrete and Construction Materials · Additive Manufacturing and 3D Printing Technologies · BIM and Construction Integration

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

Affiliations

Department of Civil & Infrastructure Engineering, RMIT University, Melbourne, Australia.

CIRTech Institute, Ho Chi Minh City University of Technology (HUTECH), Ho Chi Minh City, Viet Nam.

Singapore Centre for 3D Printing, School of Mechanical & Aerospace Engineering, Nanyang Technological University, Singapore.

Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati, India.

Department of Electrical & Biomedical Engineering, RMIT University, Melbourne, Australia.

Research group 3DInnovation, Stellenbosch University, Stellenbosch, South Africa.

Department of Mechanical Engineering, Nelson Mandela University, Port Elizabeth, South Africa.

References (100+)

Show source-provided references
1. 10.1016/j.autcon.2017.12.03110.1016/j.autcon.2017.12.031 ↗
2. 2. Jha KN. Formwork for Concrete Structures. New Delhi: Tata McGraw Hill Education Private Limited, 2012.
3. 10.1016/j.jclepro.2020.12124510.1016/j.jclepro.2020.121245 ↗
4. 10.1016/j.cemconres.2020.10607010.1016/j.cemconres.2020.106070 ↗
5. 10.1016/j.cemconres.2019.02.01710.1016/j.cemconres.2019.02.017 ↗
6. 10.1080/17452759.2018.154806910.1080/17452759.2018.1548069 ↗
7. 10.1016/j.conbuildmat.2020.11878510.1016/j.conbuildmat.2020.118785 ↗
8. 10.1016/j.cemconcomp.2019.10340610.1016/j.cemconcomp.2019.103406 ↗
9. 10.1146/annurev.energy.26.1.30310.1146/annurev.energy.26.1.303 ↗
10. Gavriletea MD. · Analysis of sand market. Sustainability · 2017 · 9 · 1118
11. 10.1038/s43017-020-0093-310.1038/s43017-020-0093-3 ↗
12. 10.1016/j.autcon.2020.10308410.1016/j.autcon.2020.103084 ↗
13. Bi M · Addit Manuf · 2020 · 36 · 101422
14. 10.1016/j.engstruct.2020.11019510.1016/j.engstruct.2020.110195 ↗
15. 15. Martens P, Mathot M, Bos F, et al. Optimising 3D printed concrete structures using topology optimisation. In: High Tech Concrete: Where Technology and Engineering Meet. Cham: Springer, 2017; pp. 301–309.10.1007/978-3-319-59471-2_37 ↗
16. 10.1007/s43452-020-00038-w10.1007/s43452-020-00038-w ↗
17. 10.1080/17452759.2016.120986710.1080/17452759.2016.1209867 ↗
18. 10.1016/j.cemconres.2018.06.00110.1016/j.cemconres.2018.06.001 ↗
19. 10.1016/j.autcon.2016.04.00510.1016/j.autcon.2016.04.005 ↗
20. Perkins I · Int J Constr Manage · 2015 · 15 · 1
21. 10.1016/j.cemconres.2020.10603710.1016/j.cemconres.2020.106037 ↗
22. 10.1016/j.cemconres.2020.10607110.1016/j.cemconres.2020.106071 ↗
23. 10.1007/s11837-020-04158-910.1007/s11837-020-04158-9 ↗
24. 10.1016/j.conbuildmat.2019.02.14410.1016/j.conbuildmat.2019.02.144 ↗
25. 10.1016/j.conbuildmat.2019.05.14010.1016/j.conbuildmat.2019.05.140 ↗
26. 10.1016/j.cemconres.2020.10607910.1016/j.cemconres.2020.106079 ↗
27. 10.1016/j.compositesa.2019.10553310.1016/j.compositesa.2019.105533 ↗
28. 10.1016/j.jclepro.2020.12388410.1016/j.jclepro.2020.123884 ↗
29. 10.3390/buildings1012024510.3390/buildings10120245 ↗
30. 10.1016/j.cemconres.2018.05.00610.1016/j.cemconres.2018.05.006 ↗
31. 10.1016/j.autcon.2019.10293310.1016/j.autcon.2019.102933 ↗
32. 10.1016/j.conbuildmat.2019.05.05310.1016/j.conbuildmat.2019.05.053 ↗
33. 10.1016/j.acme.2017.02.00810.1016/j.acme.2017.02.008 ↗
34. 10.1016/j.compstruct.2021.11405010.1016/j.compstruct.2021.114050 ↗
35. 10.1080/17452759.2017.132672410.1080/17452759.2017.1326724 ↗
36. 37. Malhotra VM, Mehta PK. High-performance, High-volume Fly Ash Concrete: Materials, Mixture Proportioning, Properties, Construction Practice, and Case Histories. Ottawa, Canada: Supplementary Cementing Materials for Sustainable Development, Incorporated, 2002.
37. 38. Beigh M, Nerella VN, Schroefl C, et al. Studying the rheological behavior of limestone calcined clay cement (LC 3 ) mixtures in the context of extrusion- based 3D-printing. Calcined Clays for Sustainable Concrete. RILEM Bookseries, Vol. 25. Singapore: Springer, 2019; pp. 229–236.10.1007/978-981-15-2806-4_26 ↗
38. 10.3390/app909180910.3390/app9091809 ↗
39. 10.3390/ma1209137410.3390/ma12091374 ↗
40. 10.1016/j.matlet.2018.11.13110.1016/j.matlet.2018.11.131 ↗
41. 10.1016/j.cemconres.2004.11.00210.1016/j.cemconres.2004.11.002 ↗
42. 10.1016/j.conbuildmat.2017.11.05010.1016/j.conbuildmat.2017.11.050 ↗
43. 10.1016/j.compositesb.2018.11.10910.1016/j.compositesb.2018.11.109 ↗
44. 10.3390/ma1213214910.3390/ma12132149 ↗
45. 10.1016/j.cemconres.2018.02.02210.1016/j.cemconres.2018.02.022 ↗
46. 10.1016/j.conbuildmat.2018.04.11510.1016/j.conbuildmat.2018.04.115 ↗
47. 48. van den Heever M, Bester F, Kruger J, et al. Effect of silicon carbide (SiC) nanoparticles on 3D printability of cement-based materials. Advances in Engineering Materials, Structures and Systems: Innovation, Mechanics and Applications, Cape Town, South Africa. London: CRC Press, 2019.10.1201/9780429426506-279 ↗
48. 10.1016/j.cemconres.2010.12.00110.1016/j.cemconres.2010.12.001 ↗
49. 10.1016/j.conbuildmat.2019.11671010.1016/j.conbuildmat.2019.116710 ↗
50. 10.1016/j.matdes.2019.10808810.1016/j.matdes.2019.108088 ↗
51. 10.1016/j.cemconres.2017.02.00910.1016/j.cemconres.2017.02.009 ↗
52. 10.1016/j.cemconres.2013.02.00110.1016/j.cemconres.2013.02.001 ↗
53. 10.1016/j.jclepro.2019.02.18510.1016/j.jclepro.2019.02.185 ↗
54. 10.1016/j.matdes.2019.10763410.1016/j.matdes.2019.107634 ↗
55. 10.1016/j.cemconres.2011.09.00410.1016/j.cemconres.2011.09.004 ↗
56. 10.1016/j.cemconcomp.2018.10.00210.1016/j.cemconcomp.2018.10.002 ↗
57. 10.1016/j.conbuildmat.2017.04.13910.1016/j.conbuildmat.2017.04.139 ↗
58. 10.1016/j.conbuildmat.2020.11978810.1016/j.conbuildmat.2020.119788 ↗
59. 10.1016/j.compositesb.2019.10729010.1016/j.compositesb.2019.107290 ↗
60. 61. Bong SH, Nematollahi B, Nazari A, et al. Fresh and hardened properties of 3D printable geopolymer cured in ambient temperature. In: First RILEM International Conference on Concrete and Digital Fabrication—Digital Concrete 2018. DC 2018. Cham: Springer, 2019.10.1007/978-3-319-99519-9_1 ↗
61. 10.3390/ma1206090210.3390/ma12060902 ↗
62. 10.1016/j.ceramint.2018.03.03110.1016/j.ceramint.2018.03.031 ↗
63. 10.1016/j.compositesb.2020.10782610.1016/j.compositesb.2020.107826 ↗
64. 10.1016/j.jclepro.2020.12098610.1016/j.jclepro.2020.120986 ↗
65. 10.1016/j.jclepro.2017.08.16510.1016/j.jclepro.2017.08.165 ↗
66. 10.1016/j.matlet.2017.07.12310.1016/j.matlet.2017.07.123 ↗
67. 10.1016/j.cemconcomp.2019.10349810.1016/j.cemconcomp.2019.103498 ↗
68. 10.3390/ma1112235210.3390/ma11122352 ↗
69. 10.1016/j.measurement.2017.08.05110.1016/j.measurement.2017.08.051 ↗
70. 10.1016/j.cemconres.2004.01.02110.1016/j.cemconres.2004.01.021 ↗
71. 10.1016/j.cemconcomp.2019.10340310.1016/j.cemconcomp.2019.103403 ↗
72. 10.1016/j.compositesb.2020.10782110.1016/j.compositesb.2020.107821 ↗
73. 10.3390/ma1112241510.3390/ma11122415 ↗
74. 10.1016/j.conbuildmat.2019.11739110.1016/j.conbuildmat.2019.117391 ↗
75. 10.1016/j.conbuildmat.2020.11830510.1016/j.conbuildmat.2020.118305 ↗
76. 10.1016/j.cemconcomp.2020.10357110.1016/j.cemconcomp.2020.103571 ↗
77. 10.1617/s11527-015-0601-y10.1617/s11527-015-0601-y ↗
78. 10.1617/s11527-015-0595-510.1617/s11527-015-0595-5 ↗
79. 10.1016/j.conbuildmat.2018.04.01710.1016/j.conbuildmat.2018.04.017 ↗
80. 10.1016/j.cemconcomp.2020.10357010.1016/j.cemconcomp.2020.103570 ↗
81. 10.1016/j.autcon.2019.10300510.1016/j.autcon.2019.103005 ↗
82. 10.1007/s00158-013-1021-710.1007/s00158-013-1021-7 ↗
83. 10.1016/j.matdes.2019.10816410.1016/j.matdes.2019.108164 ↗
84. 10.1007/s00158-018-1994-310.1007/s00158-018-1994-3 ↗
85. 87. Bartels N, Houben T. Structural optimization for 3D printing. In: Department of the Built Environment 3D Concrete Printing. Netherland: Eindhoven University of Technology, 2016; p. 102.
86. 88. van Alphen JMJ. Structural optimization for 3D concrete printing. Eindhoven University of Technology, 2017.
87. 10.1007/BF0165094910.1007/BF01650949 ↗
88. 10.1108/0264440981024412910.1108/02644409810244129 ↗
89. 10.1016/j.finel.2007.06.00610.1016/j.finel.2007.06.006 ↗
90. Aremu A · Loughborough University
91. 94. Ghabraie K, Xie Y, Huang X. Using BESO method to optimize the shape and reinforcement of underground openings. In: Challenges, Opportunities and Solutions in Structural Engineering and Construction. London: CRC Press, 2009; p. 6.
92. 95. Yan X, Dingwen B, Xie YM. A new form-finding method for shell structures based on BESO algorithm. In: International Association for Shell and Spatial Structures (IASS). Barcelona, Spain: Form and Force, 2019.
93. 10.1007/978-981-13-8153-9_1810.1007/978-981-13-8153-9_18 ↗
94. 10.1007/s00158-016-1433-210.1007/s00158-016-1433-2 ↗
95. 99. Gu W. On challenges and solutions of topology optimisation for aerospace structural design. In: 10th World Congress on Structural and Multidisciplinary Optimization. Orlando, Florida: International Society for Structural and Multidisciplinary Optimization (ISMMO), 2013; p. 1.
96. 10.1061/(ASCE)ST.1943-541X.000245410.1061/(ASCE)ST.1943-541X.0002454 ↗
97. 102. Wolfs R. 3D Printing of Concrete Structures. Eindhoven: Eindhoven University of Technology, 2015.
98. 103. Vantyghem G, Steeman M, De Corte W, et al. Design optimization for 3D concrete printing: Improving structural and thermal performances. In: Second RILEM International Conference on Concrete and Digital Fabrication. Cham: Springer International Publishing, 2020.10.1007/978-3-030-49916-7_72 ↗
99. 10.1007/s00158-019-02330-710.1007/s00158-019-02330-7 ↗
100. 10.1016/j.autcon.2020.10352910.1016/j.autcon.2020.103529 ↗