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Design Space Exploration of Printable Geometries with Cementitious Materials

Abstract : In the last ten years, additive manufacturing of cementitious material or Concrete 3D Printing has gone through exponential development both in academic and industrial fields. This technology consists of stacking layers of fresh mortar deposited with a robot. The process does not need any formwork to support the structure during the fabrication and hence allows much more architectural freedom than traditional casting methods. It can therefore be used to minimise the quantity of material used and increase overall productivity. However, mastering the 3D Printing process is still a challenge today. It requires a good understanding of the fresh material properties, the structural behaviour during the fabrication and the robotic constraints. This complexity may explain why most 3D Printing objects today are mainly vertical extrusion of a planar geometry limiting the design space of achievable geometries.The present study aims at exploring the design space of printable geometries by looking at the possibility to generate cantilevers, despite the poor properties of the fresh material. By looking at existing masonry structures like vaults and domes, built without formwork, a first insight on the interaction between the additive manufacturing process and the potential resulting geometries is proposed. This leads to the proposal of a new workflow for the design and fabrication of 3D Printed structures with cementitious material. The workflow distinguishes the analysis at the scale of the structure from the analysis at the scale of the extruded material. Regarding the former, a computational approach for the piecewise form-finding of printable structures is proposed. This approach is inspired by the design process of funicular masonry vaults but takes into consideration the fresh concrete properties and its evolution in time. The analysis at the scale of the extruded material consists of the characterisation of the Layer Pressing strategy that allows perfect control of the layer geometry and, by extension, more geometric freedom at the scale of the final structure.
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Submitted on : Monday, May 9, 2022 - 4:26:15 PM
Last modification on : Thursday, May 12, 2022 - 3:47:43 AM
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  • HAL Id : tel-03662895, version 1



Paul Carneau. Design Space Exploration of Printable Geometries with Cementitious Materials. Other. École des Ponts ParisTech, 2021. English. ⟨NNT : 2021ENPC0012⟩. ⟨tel-03662895⟩



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