article · Results in Engineering
Evaluating the mechanical characteristics of high-performance concrete reinforced with 3D-printed trusses demonstrates a viable approach to altering material behaviour. Using fused deposition modelling, four polylactic acid truss configurations: Pratt, Howe, Warren, and Warren with vertical members, were designed and cast into concrete specimens. Following a twenty-eight-day curing period, four-point bending tests revealed notable performance changes compared to plain control samples. The inclusion of the 3D-printed trusses reduced the overall weight of the specimens by between 0.5 and 2.5 kilograms. Among the evaluated designs, the Warren truss configuration yielded the highest flexural strength, elevating capacity from 24.4 kilonewtons to 27.9 kilonewtons. Furthermore, every tested truss geometry enhanced energy absorption and converted the failure mode of the high-performance concrete from brittle collapse to ductile behaviour.
Concrete structures typically suffer from heavy weight and sudden brittle failure under extreme stress. Using additive manufacturing to produce internal polymer reinforcements offers a method to create lighter concrete elements that absorb more energy and fail gradually. This shift to ductile fracture provides vital warning before structural collapse, presenting new opportunities for designing safer and more resource-efficient concrete components.
This experimental research demonstrates an applied, early-stage method for precast concrete manufacturers and structural component designers seeking lighter building materials with enhanced ductility. While additive manufacturing of internal polymeric trusses improves flexural strength and energy absorption, testing remains at laboratory-scale specimen level. Commercial viability will require scaling production beyond small mould fabrication to industrial manufacturing processes and verifying performance under broader environmental conditions.
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The present study aims to explore the feasibility of employing 3D printing technology in reinforcing High Performance Concrete (HPC). To this end, the mechanical characteristics of HPC reinforced with four types of 3D-printed trusses (Pratt, Howe, Warren and Warren with vertical members) made from Polylactic Acid (PLA) have been evaluated. The 3D-printed truss reinforcements were plotted with the aid of 3D Max software. Then, they were produced using the Fused Deposition Modeling (FDM) technique and were placed into the molds. After that, the HPC mixture was poured into the molds and the specimens were cured for 28 days. Finally, the four-point bending tests were conducted on the specimens. The results showed that the employment of different 3D-printed trusses reduced the weight of the control samples between 0.5 and 2.5 kg. In addition, the application of 3D-printed Warren truss had the best performance among other types of trusses in terms of the flexural strength so that it increased the flexural strength of the control sample from 24.4 to 27.9 kN. Finally, all types of 3D-printed trusses increased the energy absorption capacity and were able to alter the fracture mechanism of HPC from brittle to ductile.
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DOI: 10.1016/j.rineng.2024.102058
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