Design Optimization for 3D Concrete Printing: Improving Structural and Thermal Performances

Abstract

This paper focuses on optimizing the shape of prefabricated building components that are produced using 3D concrete printing (3DCP) techniques. The proposed method is to improve the structural and thermal properties using heuristic optimization algorithms, as such that they meet the minimum standards determined by building design codes. First, a case study is constructed that is based upon an existing module design found in literature, and a single segment from this design is isolated. The influence of the overall shape and the curvature of the infill line is investigated, and the structural performance is optimized for the hardened material state. In a second attempt, the heat transfer through the segment is also minimized. In parallel to the design’s optimization process, of course, the manufacturing challenges and process limitation need to be considered as well. Therefore, the influence of the infill line on the buildability of a 3DCP element is also demonstrated in a fresh material state (i.e. during printing). For this, the complete printing process of a wall segment is simulated and allows for the prediction of printing failure, elastic buckling and plastic collapse. Based on the outcome of the FEM-based calculations, a design could then be marked fit for printing or allow for further optimization.