3D printing of mortar with continuous fibres: Principle, properties and potential for application

• Published in: Automation in construction 2021-09, Vol.129, p.103806, Article 103806
• Main Authors: Caron, Jean-François, Demont, Léo, Ducoulombier, Nicolas, Mesnil, Romain
• Format: Article
• Language: English
• Subjects: Additive manufacturing; Anisotropic concrete; Basalt; Component reliability; Composite materials; Concrete printing; Construction standards; Continuous fibers; Engineering Sciences; Fiber reinforced concrete; Load bearing components; Manufacturing; Materials handling; Mortars (material); Pultrusion; Rheological properties; Three dimensional printing
• ISSN: 0926-5805; 1872-7891
• DOI: 10.1016/j.autcon.2021.103806

Important developments in additive manufacturing with concrete have been achieved in the past decades. Yet, printed components usually do not comply with building standards or basic reliability principles, and are not commonly used as load-bearing components. A gap between research and practice exists and despite several attempts, off-the-shelf commercial solutions for the reinforcement of the 3D printed structural components seem always expected. This article presents an alternative (pending for patent [1]) for reinforcement of 3D printed structures. This technology inspired by the composite industry is called Flow-Based Pultrusion for additive manufacturing (FBP). A strict control of the rheological behavior of the cementitious matrix ensures the routing and impregnation of continuous rovings of thin fibres (glass, basalt, etc.) without any motorization. The resulting material, Anisotropic Concrete, homogeneously reinforced in a single direction, provides new possibilities, may enhance strength and ductility for hardened material but also help to a better handling of the fresh laces during the deposition, permitting inclined or cantilever paths. This paper describes the process, its constraints, first experimental achievements and first investigations about the mechanical performances of such a material. •Flow-based reinforcement of 3D printed structures with continuous fibres.•Anisotropic Concrete for new optimised constructive solutions.•No motorization needed for fiber deposition.•Easier handling of the reinforced fresh lace, avoiding slug and buckling.•Reinforcement of the hardened material, improvement of strength and ductility.