{"id":151119,"date":"2025-05-13T12:03:59","date_gmt":"2025-05-13T11:03:59","guid":{"rendered":"https:\/\/www.pbctoday.co.uk\/news\/?p=151119"},"modified":"2025-05-13T12:10:33","modified_gmt":"2025-05-13T11:10:33","slug":"new-study-finds-25-material-savings-through-thickness-optimisation-3d-printed-concrete","status":"publish","type":"post","link":"https:\/\/www.pbctoday.co.uk\/news\/mmc-news\/new-study-finds-25-material-savings-through-thickness-optimisation-3d-printed-concrete\/151119\/","title":{"rendered":"New study finds 25% material savings through thickness optimisation in 3D printed concrete"},"content":{"rendered":"

A team of French researchers has announced a breakthrough in the sustainable use of materials in 3D printed concrete, introducing a novel optimisation framework<\/a> that reduces material use by up to 25%\u2014without compromising structural integrity<\/h2>\n

The study, led by Dr. Romain Mesnil at \u00c9cole des Ponts ParisTech and published in Automation in Construction<\/em><\/a>, demonstrates that variable layer thickness, dynamically adjusted through robot velocity, can significantly reduce both printing time and environmental impact in additive manufacturing of concrete shell structures.<\/p>\n

\u201cThis research shows that by leveraging the capabilities of robotic printing, we can move beyond constant layer designs and make data-driven decisions about where material is truly needed,\u201d said Dr. Mesnil. \u201cIt\u2019s a step-change toward greener, smarter construction.\u201d<\/p>\n

A new dimension in 3DCP process optimisation<\/h3>\n

The work challenges the status quo in 3D concrete printing (3DCP)<\/a>, where most systems rely on uniform wall thickness due to modelling complexity and lack of real-time optimisation tools.<\/p>\n

The team\u2019s model simulates the printing process using a lightweight finite element analysis (FEA) approach based on shell elements, significantly reducing computation time while maintaining accuracy.<\/p>\n

\"\"
Image via Automation in Construction<\/figcaption><\/figure>\n

Key innovations include:<\/h4>\n
    \n
  • A parametric optimisation routine that links process parameters (flow rate, nozzle speed) with material deposition profiles.<\/li>\n
  • Use of Bezier splines to control thickness gradients across printed layers.<\/li>\n
  • Integrated numerical convergence analysis ensuring mechanical reliability against buckling and failure.<\/li>\n
  • Validation through full-scale printing experiments on complex shapes like domes and hourglass shells using a 2K mortar system and robotic arm from XTreeE.<\/li>\n<\/ul>\n

    Significant gains in efficiency<\/h3>\n

    Across multiple tests, variable thickness printing achieved:<\/p>\n

      \n
    • Up to 25% reduction in concrete use<\/li>\n
    • 20% decrease in cost compared to conventional printing<\/li>\n
    • Greater structural stability during critical printing stages<\/li>\n<\/ul>\n

      The hourglass-shaped test showed especially strong gains: variable thickness designs outperformed constant thickness in every performance metric, including material efficiency, time, and cost.<\/p>\n

      A pathway to scalable sustainable construction<\/h3>\n

      By adopting this optimisation framework, manufacturers can:<\/p>\n

        \n
      • Reduce carbon emissions tied to concrete use<\/li>\n
      • Accelerate print times and throughput<\/li>\n
      • Gain flexibility in balancing productivity with environmental performance<\/li>\n<\/ul>\n

        The team also introduced a design-to-print workflow compatible with Grasshopper and Karamba (Rhino plugins), ensuring smooth integration into existing parametric design and simulation environments.<\/p>\n

        \n<\/div>","protected":false},"excerpt":{"rendered":"

        A team of French researchers has announced a breakthrough in the sustainable use of materials in 3D printed concrete, introducing a novel optimisation framework that reduces material use by up to 25%\u2014without compromising structural integrity. <\/p>\n","protected":false},"author":25,"featured_media":151128,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"footnotes":""},"categories":[942],"tags":[811,273],"stakeholder_rel_tag":[],"contributor_rel_tag":[],"class_list":{"0":"post-151119","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-mmc-news","8":"tag-concrete","9":"tag-research-innovation"},"acf":[],"yoast_head":"\nNew study finds 25% material savings through thickness optimisation in 3D 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