Parametric analysis of design and operational parameters in 3D concrete printing of wall elements

The transformative potential of 3D concrete printing (3DCP) in construction is increasingly evident, promising enhanced precision, reduced waste, greater design flexibility, and improved cost and energy efficiency. However, challenges remain in process optimization, material formulation, and industrial scalability. Integrating advanced numerical modeling with experimental validation is essential for accurately predicting structural behavior, minimizing defects, and developing robust printing strategies. This study employed validated numerical models to analyze failure mechanisms and structuration performance of 3D-printed wall elements across various geometric configurations, and printing parameters. Validation was performed using data from literature and laboratory experiments. A parametric study examined key factors like wall geometry, layer width, and operational parameters affecting structuration (i.e., buildability) performance. Results highlighted the significant influence of pre-design decisions, with overall structural design and layer dimensions proving critical to stability. Specifically, low-aspect-ratio walls increased maximum printable height by up to 330 %. In addition, layer aspect ratio improved performance by up to 145 % in the base configuration, while printing speed accounted for only about a 30 % variation in height, underscoring its secondary role. By systematically exploring design and process interactions, the research identifies optimal configurations that enhance structuration while minimizing instability risks. These insights contribute to the broader adoption of 3DCP by addressing potential issues during the design phase. This work underscores the importance of tailored pre-design strategies in optimizing 3DCP for sustainable, scalable, and efficient construction practices.