Parametric Experimental and Numerical Optimization of 3D Concrete Printing for Enhanced Efficiency in Modular Construction Systems
Keywords:
3D concrete printing, modular construction, process optimization, buildability, interlayer bonding, construction efficiency, digital fabricationAbstract
Three-dimensional concrete printing (3DCP) is an emerging construction technology that integrates digital fabrication, automation, and modular construction to improve productivity, reduce material waste, and address labor shortages. However, its application remains limited due to insufficient understanding of the relationship between process parameters, construction efficiency, and structural performance. This study develops and evaluates a parametric framework linking key 3DCP variables to modular construction performance. An experimental–numerical approach was used to assess the effects of printing speed, layer height, nozzle diameter, fiber content, and mix design on buildability, dimensional accuracy, surface quality, compressive strength, interlayer bond strength, material waste, and construction efficiency. Statistical analyses, including ANOVA, response surface methodology, and multi-objective optimization, were employed to identify optimal parameter ranges. Results indicate that 3DCP performance depends strongly on the interaction between material rheology and printing parameters. Optimal performance was achieved at printing speeds of 75–100 mm/s, layer heights of 10–12 mm, nozzle diameters of approximately 20 mm, and fiber content of around 0.5%, resulting in improved extrusion stability, dimensional accuracy, and interlayer bonding. Interlayer bonding was identified as the key factor affecting structural integrity and collapse resistance. Optimized parameter settings reduced construction time by 40–60% and material waste by up to 45% compared with conventional methods. Nevertheless, trade-offs between extrudability and mechanical performance were observed, particularly due to variations in fiber content and deposition intervals. The findings highlight the importance of integrated optimization of material composition and process parameters to support future adaptive and digital twin-based modular construction systems.
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