Automated shotcrete 3D printing – Printing interruption for extended component complexity

Abstract

This paper presents a novel approach to extending the geometrical freedom of shotcrete 3D printing (SC3DP). Traditionally, continuous material flow has been necessary to prevent nozzle clogging, which occurs when fresh material solidifies inside the printing system. However, this requirement restricts the process to continuous printing paths, limiting the range of printable geometries.

To address this challenge, potential factors for controlling printing interruptions were identified and quantitatively analyzed. Using 3D specimen data, the study determined optimal parameter settings that enable deterministic short-term printing gaps without causing nozzle blockage.

For final validation, these parameters were applied in the robotic fabrication of a test element, which demonstrated promising results. This approach offers a breakthrough in robotic construction, paving the way for more complex geometries in concrete 3D printing and expanding possibilities in construction robotics and automation.