Three-dimensional concrete printing (3DCP) is an emerging construction technique that uses an automated robotic system to build structures out of concrete. A 3D concrete printer consists of a concrete material delivery system that mixes and pumps concrete through a hose to a nozzle held by a robotic arm or gantry. This technology enables the construction of complex designs that would be time-consuming and expensive to achieve using traditional concrete construction methods. The automation provided by 3DCP has several advantages including reducing waste, construction time, and labor costs.
How does 3D concrete printing work?
Creating a 3D model
The first step in 3D concrete printing is to create a 3D model of the design using a computer-aided design (CAD) program. The flexibility of 3DCP allows designers to push the boundaries and explore more complex, innovative, and organic designs. Parametric design tools can be used to develop complicated, varied geometries in an automated manner.
Generating instructions for the robot
The next step is to generate instructions for the printer to follow. The 3D model is first sliced into layers to create a path that the printer nozzle will follow. This print path is then converted into a code that contains instructions on the robot’s movement, and concrete pump speed. Before uploading to the printer, the instructions are checked for potential errors, ensuring quality and safety during the print.
Material preparation
3D concrete printers most often use specialized pre-batched dry materials, which must be mixed with water at a prescribed ratio. The pump is first primed with water and a cement slurry. Then, the feed rates of water and dry concrete material are adjusted until the correct consistency is reached.
Printing
Once ready, the printing routine is initiated. The printer moves the nozzle along the print path, depositing concrete layer by layer, until the object is completed. Minimal human intervention is needed during printing; printers can be operated by a crew of 2-3 people.
3D Concrete Printing and Renewable Energy
RCAM Technologies uses 3D concrete printing technology to create low-cost, locally manufactured renewable energy components. Our 3D printed concrete products include wind turbine towers; anchors for floating offshore wind, wave, and solar energy; and an innovative subsea energy storage technology. 3DCP offers a versatile, lean, and scalable method to fabricate these components with the benefits of reducing material and labor costs, utilizing existing supply chains, and creating domestic jobs in 3DCP engineering and construction. Overall, 3DCP is poised to play a major role in the renewable energy transition.
