SEARCH · Search NASA

Results for “3D printing concrete”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 37 records · Page 2

All sources NASA NTRS DOE OSTI

DOE OSTI2021

Qualification of 3-D Printed Mortar With Electrical Conductivity Measurements

Additive manufacturing (AM) or 3D printing of concrete allows for construction of arbitrary shape structures without a mold. Since reproducibility of 3D printed concrete is lower than that of conventional fabrication, each 3D printed structure should be monitored for proper curing. Conventional qualification of concrete is based on several tests, including destructive compressive strength measurements. Because a structure is 3-D printed layer-by-layer, the surfaces of AM concrete structures have significant surface roughness. This limits the applicability of conventional nondestructive testing methods. We investigated qualification of 3D printed mortar by monitoring curing with nondestructive electrical conductivity measurements. Bulk resistance of concrete was extracted from electrochemical impedance spectroscopy (EIS measurements made using custom flexible self-adhesive electrodes, which contour to rough surfaces. We show that bulk resistivity of concrete increases linearly with time. This allows for developing a calibration curve for compressive strength lookup from nondestructive electrical conductivity measurements. Conductivity measurements also allow for estimation of formation factor, which is an indicator of mortar permeability.

36 MATERIALS SCIENCE↗

DOE OSTI2024

On the Flow of a Cement Suspension: The Effects of Nano-Silica and Fly Ash Particles

Additives such as nano-silica and fly ash are widely used in cement and concrete materials to improve the rheology of fresh cement and concrete and the performance of hardened materials and increase the sustainability of the cement and concrete industry by reducing the usage of Portland cement. Therefore, it is important to study the effect of these additives on the rheological behavior of fresh cement. In this paper, we study the pulsating Poiseuille flow of fresh cement in a horizontal pipe by considering two different additives and when they are combined (nano-silica, fly ash, combined nano-silica, and fly ash). To model the fresh cement suspension, we used a modified form of the power-law model to demonstrate the dependency of the cement viscosity on the shear rate and volume fraction of cement and the additive particles. The convection–diffusion equation was used to solve for the volume fraction. After solving the equations in the dimensionless forms, we conducted a parametric study to analyze the effects of nano-silica, fly ash, and combined nano-silica and fly ash additives on the velocity and volume fraction profiles of the cement suspension. According to the parametric study presented here, larger nano-silica content results in lower centerline velocity of the cement suspension and larger non-uniformity of the volume fraction. Compared to nano-silica, fly ash exhibits an opposite effect on the velocity. Larger fly ash content results in higher centerline velocity, while the effect of the fly ash on the volume fraction is not obvious. For cement suspension containing combined nano-silica and fly ash additives, nano-silica plays a dominant role in the flow behavior of the suspension. The findings of the study can help the design and operation of the pulsating flow of fresh cement mortars and concrete in the 3D printing industry.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Effect of Interlayer Time-Lapse and Workability Retention on Printed Concrete Performance

The rapid advancement of additive manufacturing technologies for concrete construction requires further understanding of material performance and its relationship with print parameters such as interlayer time-lapse and workability retention during the print. Here this study addresses the effects of the time delay between consecutive extruded layers on the mechanical performance of printed concrete using a mix designed by Quikrete. A series of specimens were prepared with printing delays of 10, 15, 30, and 60 min. This work correlates the change in fracture properties, mechanical performance, and workability retention with the interlayer time-lapse between two consecutive concrete layers. Interlayer time-lapse is defined as the time difference in printing of two consequent layers of concrete. It affects individual properties differently based on the loading direction and test types, but it is consistent in terms of interlayer performance. The understanding of the effect of interlayer time-lapse on the fracture properties between two consecutive printed layers fills the knowledge gaps in printed concrete research. Therefore, this study can help researchers perform required optimization and safely estimate the performance of printed concrete.

3D printing↗

DOE OSTI2026

Biodegradable Biocomposite Development for Large Scale Additive Manufacturing

Oak Ridge National Laboratory (ORNL) worked with Mitsubishi Chemical America, Inc. to develop a highly biodegradable ~100% biobased feedstock for large format additive manufacturing (AM). Together, they developed a AM feedstock based on the biobased polyester, polybutylene succinate (PBS), that is typically used in agriculture and packaging projects. The motivation for this work was to leverage the high degradability of this polymer in AM to create a new avenue for end-of-life disposal of the product. A composite feedstock was developed from PBS, polylactic acid (PLA), and wood flour (WF). While WF improves printability, reduces feedstock cost, and can improve stiffness, it also often results in a loss in tensile strength which can inhibit/limit application of the material. To recover the loss in tensile strength suffered by including large quantities, up to 30 wt%, WF in the composite a chain extender was used to compatibilze the different composite constituents with each other. The feedstock was used to 3D-print demonstration mold for precast concrete catch basins and was tested by casting 750 lbs of concrete. The mold survived the demonstration. Aerobic degradation testing of the composite feedstock showed that it was highly degradable, 40% biodegradation after 90 days, compared to other incumbent biobased feedstocks.

36 MATERIALS SCIENCE↗

DOE OSTI2025

3D Printing of Cement-Based Materials Using Seawater for Simulated Marine Environments

Global demand for adaptable and rapidly deployable construction solutions in offshore, coastal, and fluvial environments continues to rise, driven by pressing needs to develop energy platforms, improve coastal resilience, and support emergency response in the face of natural disasters. Increased investment in human-made coastal infrastructure, such as piers, support structures for power lines, offshore wind farms, and seawall protection systems, further underscores this trend. This study investigates the development of printable concrete mixtures for underwater environments using seawater as a replacement for freshwater, using a 3D printing syringe-based extrusion system. The effect of seawater addition and the printing medium (in air vs. underwater) was assessed via rheological and mechanical performance characterization. The results indicate rheological properties are favorable for seawater adoption by producing mixtures with higher yield stress and viscosity with the same levels of admixtures used for freshwater. Seawater-based mixtures demonstrated superior dimensional stability compared to freshwater counterparts, maintaining cross-sectional geometry, while compressive strength results showed no statistical differences between in-air and underwater samples. However, flexural strength was significantly influenced by geometry and printing medium. These findings establish critical rheological parameters for printable underwater mixtures and highlight the need for optimized curing strategies and layer bonding techniques to improve interfacial strength in underwater 3D printing applications.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Biodegradable Biocomposite Development for Large Scale Additive Manufacturing

Oak Ridge National Laboratory (ORNL) worked with Mitsubishi Chemical America, Inc. to develop a highly biodegradable ~100% biobased feedstock for large format additive manufacturing (AM). Together, they developed an AM feedstock based on the biobased polyester, polybutylene succinate (PBS), that is typically used in agriculture and packaging projects. The motivation for this work was to leverage the high degradability of this polymer in AM to create a new avenue for end-of-life disposal of the product. A composite feedstock was developed from PBS, polylactic acid (PLA), and wood flour (WF). While WF improves printability, reduces feedstock cost, and can improve stiffness, it also often results in a loss in tensile strength which can inhibit/limit applications of the material. To recover the loss in tensile strength suffered by including large quantities, up to 30 wt.% WF in the composite, a chain extender was used to compatibilize the different composite constituents with each other. The feedstock was used to 3D-print a demonstration mold for precast concrete catch basins and was tested by casting 750 lbs of concrete. The mold survived the demonstration. Aerobic degradation testing of the composite feedstock showed that it was highly degradable, 40% biodegradation after 90 days, compared to other incumbent biobased feedstocks.

100% biobased feedstock for large format additive ↗

DOE OSTI2024

Use of a Lignin-Based Admixture for Tailoring the Rheological Properties of Mortars for 3D Printing: Preprint

Efforts toward decarbonizing construction materials and industrial processes related to cement and concrete can be aided via multifaceted approaches that target alternative admixtures as well as precision control of fabrication. Chemical admixtures for water reduction have played a crucial role in the development of advanced concrete mixtures. Newer biomass processing techniques developed for aviation fuel production from corn stover biomass produce a more reactive lignin byproduct that is suitable for chemical modifications to mimic the properties of polycarboxylate ether admixtures with a smaller carbon footprint. The present study examines the use of lignin-based water-reducing admixture in cement pastes and mortar mixtures for 3D printing. The experimental program explores the use of different dosages of lignin-based admixture to produce 3D-printed samples with appropriate extrudability and buildability. The rheological characterization was performed to determine the flow curve of various mixtures. Finally, the heat of hydration of cement pastes was monitored via isothermal calorimetry to assess the impact of lignin-based admixtures on the hydration process of cement. The results of this study indicate that the use of biomass by-products, such as lignin-based admixtures have great potential to effectively control the fresh-state properties of cement-based materials.

bio-based admixtures↗

DOE OSTI2024

Use of Lignin-Based Admixture as Water Reducer (WRA) for Tailoring the Rheological Properties of Mortars for 3D-Printing

Efforts towards decarbonizing construction materials and industrial processes related to cement and concrete can be aided via multifaceted approaches that target alternative admixtures as well as precision control of fabrication. Chemical admixtures for water reduction have played a crucial role in the development of advanced mortar and concrete mixtures. Newer biomass processing techniques developed for aviation fuel production from corn stover biomass produce a highly reactive lignin byproduct that is suitable for chemical modifications to mimic the properties of commonly used polycarboxylate ethers (PCEs) with a smaller carbon footprint. These lignin-based plasticizers developed at NREL can be used in place of petrochemical-derived superplasticizers to tailor the rheological properties of cement-based systems for applications such as additive manufacturing while reducing the carbon intensity of the concrete mix. Lignosulfonates derived from paper pulping were historically used as water reducers only to be displaced with the rise of PCEs. The present study examines the use of a NREL produced lignin-based water reducing admixture (WRA), in cement pastes and mortar mixtures for 3D-printing at small- (mm) scale. The experimental program consisted of different formulations of oxidized lignin-based WRAs added in variable dosages to cement pastes with a fixed water-to-cement ratio. The objective is to achieve an appropriate workability, extrudability and buildability of mortar mixtures to produce 3D-printed specimens. The rheological characterization was performed to compare the initial yield stress and viscosity of the different mixtures with lignin-based admixture with respect to conventional PCE superplasticizers. The rheological characterization shows that the proposed material act as an effective water-reducer in cement systems, affecting the yield stress, plastic viscosity, and structuration rate of the mixtures evaluated. On the other hand, the effect on early hydration process of the cement pastes containing lignin-based admixtures is comparable to conventional superplasticizers.

3D-printing↗

NASA NTRS2018

Additive Construction with Mobile Emplacement (ACME) / Automated Construction of Expeditionary Structures (ACES) Materials Delivery System (MDS)

The purpose of the Automated Construction of Expeditionary Structures, Phase 3 (ACES 3) project is to incorporate the Liquid Goods Delivery System (LGDS) into the Dry Goods Delivery System (DGDS) structure to create an integrated and automated Materials Delivery System (MDS) for 3D printing structures with ordinary Portland cement (OPC) concrete. ACES 3 is a prototype for 3-D printing barracks for soldiers in forward bases, here on Earth. The LGDS supports ACES 3 by storing liquid materials, mixing recipe batches of liquid materials, and working with the Dry Goods Feed System (DGFS) previously developed for ACES 2, combining the materials that are eventually extruded out of the print nozzle. Automated Construction of Expeditionary Structures, Phase 3 (ACES 3) is a project led by the US Army Corps of Engineers (USACE) and supported by NASA. The equivalent 3D printing system for construction in space is designated Additive Construction with Mobile Emplacement (ACME) by NASA.

Mueller, R. P.↗

DOE OSTI2021

Assessment of asymmetrical rheological behavior of cementitious material for 3D printing application

Among the multiplicity of construction methods based on digital concrete technologies, the most common one remains the extrusion-based process. Two opposed strategies have been developed in order to print a concrete structure using extrusion: the first one emphasizes the ease-of-pumping of material which is massively accelerated to ensure the stability of the structure, when leaving the extruder; the second one uses a firm mortar able to sustain the own weight of the structure during the printing, without requiring any accelerator. Both methods have their pros and cons and don't imply the same rheological requirements. Most of the recent literature assumes that both types of material (fluid and firm) follow the same trend of behavior and obey to the Von Mises plasticity criterion, while it has been demonstrated that firm cement-based materials can exhibit a pressure dependent behavior. Moreover, rheological study is mainly based on shear rheometry, while the extrusion-based printing process requires a description of the rheological behavior in compression to predict the global stability of the structure, and in tension to prevent cracks formation. This paper investigates the fresh behavior of cement paste and mortar under different solicitations (shear, compression, tension) for different water to cement ratios. The analysis of these results allows to describe the transition between a ductile fluid material (symmetrical in tension and compression) that obeys to a Von Mises plasticity criterion, and a brittle and firm material (asymmetrical in tension and compression) that requires a pressure dependent plasticity criterion in order to predict its strength under a given solicitation.

36 MATERIALS SCIENCE↗

DOE OSTI2023

An innovative carbonated cementitious material and its printability and carbon mineralization capacity

The main goal of this research is to develop a carbonated cementitious material (CCMs) mix design and demonstrate its rapid stiffening for manufacturing 3D printed or precast elements for building construction (i.e., concrete with enhanced durability and CO 2 capture efficiency). The material development employs hydrated Ca(OH) 2 , and its distinct reaction with CO 2 to form CaCO 3 . Different formulations and additives including polymer materials enable the thermomechanical properties that give these CCMs 3D printability comparable with cement materials used for similar applications. Here, printable and castable CCM formulations were successfully developed and demonstrated to mineralize CO 2 to form up to 57% CaCO 3 .

36 MATERIALS SCIENCE↗

DOE OSTI2023

Life cycle cost, energy, and carbon emissions of molds for precast concrete: Exploring the impacts of material choices and additive manufacturing

Molds for precast concrete are commonly used to create simple- to complex-shaped concrete products away from construction sites. These molds are often handmade from wood; however, additively manufacturing (AM, or 3D printing) fiber-reinforced polymer composites is an advantageous alternative, producing significantly more durable, highly complex molds faster, but likely at a higher cost. Here, this study explores the impact of material and production variables on the cost, energy, and carbon emissions of employing composite AM molds over the full lifecycle. The case study employed techno-economic and life cycle assessments to show that using wood flour–poly(lactic acid) or recycled carbon fiber–acrylonitrile butadiene styrene for AM molds can be less expensive than conventional wood molds, especially when considering use phase costs. While wood molds have the least environmental impacts due to wood's higher biogenic carbon sequestration and minimal processing, optimizing AM designs could reduce energy demand, carbon emissions, and cost.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Biopolymer Concrete

Cement production for concrete has been responsible for ~7–8% of global greenhouse gas (GHG) emissions, and nearly equally contribution for steel production processes (EPA, 2020). In order to achieve carbon neutrality by 2050, a novel solution has to be investigated. This project aims to develop fundamental mechanistic understanding and experimental characterization to create a 3D printable biopolymer concrete using plant-based polyurethane as an innovative and sustainable alternative for Portland cement concrete, with significantly low carbon footprint. Future construction will utilize the advances in digital additive manufacturing (3D printing) to produce optimal geometries with a minimum waste of materials. Understanding the polymerization process, factors impacting the composite rheology, and the structural behavior of this biopolymer concrete will enable us to engineer the next generation of concrete structures with low carbon footprint. This project aims to improve the nation’s ability to control Greenhouse Gas emission neutrality for the set goal of 2050 via introducing a structurally viable bio-based polymer concrete.

42 ENGINEERING↗

DOE OSTI2020

Characterization of paste microstructure for durability properties of concrete

In this study, paste samples from different cementitious systems were characterized by using X-Ray Micro Computed Tomography (µ-CT) and Fluorescence Microscopy techniques. Quantitative and qualitative aspects of defects from paste samples were investigated to develop indicators of durability related properties of corresponding concrete samples. In the first phase of this study, hour glass shaped 3D printed molds were used to investigate five cementitious combinations consisting of three cement types (Coarse Ground portland cement, Type IL Portland Limestone Cement and Type I/II ordinary portland cement) and fly ash as a supplementary cementitious material. In the second phase, metal molds were used to compare the results of Coarse Ground portland cement with Type I ordinary portland cement, 5% of which was replaced with colloidal nanosilica. Potential correlations between paste and concrete have been presented. This work was supported by US Department of Energy and North Dakota Department of Commerce.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Rheological and pumping behaviour of 3D printable cementitious materials with varying aggregate content

3D printing with cementitious materials is an emerging technology and provides an active area of research. Despite this, there are only limited studies that examine the pumping behaviour of high yield stress fluids such as printable concrete. We present a study on the rheological behaviour of 3D printable cementitious materials with different aggregate-to-binder ratios (a/b) and analyse the pumping and printing characteristics with the measured rheological parameters. We observed that an increase in a/b resulted in a significant increase of plastic viscosity, and a nominal increase in yield stress and storage modulus. The variation in plastic viscosity and yield stress with increasing aggregate content was analysed with the Krieger-Dougherty and Chateau-Ovarlez-Trung model, respectively. Also, the rheological properties of the paste rich lubrication layer during pumping were determined with the help of a tribometer. The yield stress and viscous constant of the lubrication layer increase with the increase in a/b. The pumping pressure predictions were carried out by a suitable theoretical model by considering appropriate flow conditions for different mixtures. The variation in critical height of printed elements with an increase in a/b was correlated with the observed rheological parameters.

36 MATERIALS SCIENCE↗

NASA NTRS2019

NASA Centennial Challenge: 3D Printed Habitat, Phase 3 Final Results

NASA's Centennial Challenges program uses prize competitions with the goal of accelerating innovation in the aerospace industry. Competitions in the Centennial Challenges portfolio have previously focused on advancements in space robotics, regolith excavation, bio-printing, astronaut suit design, small satellites, and solar-powered vehicles. NASA's Three Dimensional (3D) Printed Habitat Centennial Challenge represents a partnership between NASA and the non-profit partner: Bradley University, with co-sponsors Caterpillar, Bechtel, Brick and Mortar Ventures, the American Concrete Institute, and the United States Army Corps of Engineers (USACE) Engineer Research and Development Center (ERDC) to spur development in automated additive construction technologies. The challenge asks teams to design and construct a scaled and simulated Martian habitat using indigenous materials and large scale 3D automated printing systems. Phase 1 of the competition, held in 2015, was an architectural design competition for habitat concepts that could be 3D printed. Phase 2, completed in 2017, asked teams to develop feedstocks from indigenous materials and hydrocarbon polymer recyclables, and demonstrate automated printing systems to manufacture these feedstocks into test specimens to assess mechanical strength. This paper will discuss the Phase 3 competition, focusing on technology outcomes that can potentially be infused into both terrestrial and planetary construction applications. The Phase 3 competition was divided into two sub-competitions: 1) virtual construction, where teams created a high fidelity building information model (BIM) of their 3D-printed habitat design and 2) the construction competition, which required teams to 3D print a structural foundation and subject materials samples to freeze/thaw testing and impact testing (level 1), produce a habitat element and complete a hydrostatic test (level 2), and additively manufacture a 1:3 scale habitat onsite in a head to head competition at Caterpillar, inc.'s Edwards Demonstration & Learning Center near Peoria, Illinois over the course of three days (level 3). While the Phase 2 competition focused primarily on the development of novel feedstocks and robotic printing systems, Phase 3 emphasized the scale-up of these systems and autonomous operation (demonstrating the capability to operate systems on precursor missions prior to the arrival of crew, or terrestrially in field operation settings where human tending of a manufacturing system may be limited). The Phase 3 virtual construction levels yielded a number of novel habitat designs, including both modular habitats and vertically-oriented habitat concepts. The Phase 3 construction competition also challenged teams to autonomously place penetrations and interfacing elements in additively manufactured structures. The paper will emphasize potential applications for the new materials and technologies developed under the umbrella of the competition within NASA's portfolio and in Earth-based applications such as disaster response and infrastructure improvement.

Construction↗

NASA NTRS2019

Nasa Centennial Challenge: Three Dimensional (3d) Printed Habitat, Phase 3

Centennial challenge↗

DOE OSTI2024

Toolpath considerations for extrusion: Pellet, filament, concrete, and thermoset

There are a variety of extrusion and deposition-based processes for additive manufacturing, such as fused deposition modeling (FDM), fused filament fabrication (FFF), and directed energy deposition (DED). These processes can use a variety of materials, including thermoplastic pellets, thermoplastic filament, thermoset, concrete, metal wire, metal powder, and more. For all these processes and materials, the underlying toolpath strategies for 3D-printing an object are the same: the object to be printed is sliced into layers, then the layer is optimally fit with toolpaths of a given width, based on specific user settings. However, based on the specific process being used, additional modifiers and toolpathing strategies may be employed to maximize the capabilities of the process and successfully construct an object. This chapter explores the different pathing considerations and additional strategies to be employed in extrusion processes that use thermoplastics, thermosets, and concretes.

Roschli, Alex↗