Three-Dimensional Printable Concrete by an Ultra-Thin Nozzle and Fully Sealed Extrusion

Due to the molding-free property and dry shrinkage of extrusion-based three-dimensional printable concrete (3DPC), the precision issues of 3DPC have not been solved effectively. One of the viable solutions for 3DPC precision improvement is to print using ultra-thin filaments. The challenges of ultra-thin-filament printing are extrudability, flowability, and fast solidification. To overcome these challenges and enhance precision, a customized 3D concrete printer with an ultra-thin diameter nozzle (6 mm) and fully sealed extrusion system was developed, and the mix design of ultra-thin-filament 3DPC (UTF-3DPC) was studied, including ingredients such as fly ash (FA), silica fume (SF), ordinary Portland cement (OPC), sodium dodecyl sulfate and cellulose (SDSC), water reducer, water, and sand. The function of UTF-3DPCs flowability and fast solidification with the proportion of water and SDSC was explored to obtain the optimal mix design. The standard compressive and flexural strengths of UTF-3DPC specimens were compared with the mold-cast vibrated and the mold-cast non-vibrated concrete. Their meso-scale and micro-scale structures were analyzed to expose the strength mechanism, according to the scanning electron microscope (SEM) images. A suitable mix design of UTF-3DPC was obtained and UTF-3DPC strength reached 80% of standard mold-cast concrete. The findings reported here provide a pathway to improve the precision of 3DPC and extend the application of 3D printing technology in engineering.