A novel multi-method framework for 3D printed fiber-reinforced polymer concrete utilizing advance additive manufacturing techniques

Abstract

Growing demands for customized, sustainable, and high-performance infrastructure urgently require innovative construction methodologies. Conventional methods for fiber-reinforced polymer concrete are not efficient in material usage, are inconsistent in their mechanical properties, and fail to satisfy the complex structural demands. The current methods of 3D printing are often affected by delamination of layers, bad alignment of fibers, and relatively high rates of defects, which adversely affect the structural integrity and efficiency of the printed components. To address these challenges, we propose a novel multi-method framework utilizing advance additive manufacturing techniques for 3D printed fiber-reinforced polymer concrete. Our research introduces four additional mechanisms: GCMME (Gradient-Controlled Deposition via Multi-Material Extrusion) for smooth material transitions with functional graded properties, DFAM (Directional Fiber Alignment Mechanism) for optimal reinforcement along stress trajectories, ARCS (Adaptive Rheology Control System) for viscosity modulation and self-healing capabilities, and AQA-PDM (AI-Based Quality Assurance and Predictive Defect Mitigation) for real-time defect detection and quality control. All the above-mentioned mechanisms can be used simultaneously to allow for the mass production of customised structural parts with outstanding mechanical properties. Significant results include tensile strength greater than 12 MPa, compressive strength greater than 50 MPa, enhanced flexural strength by about 35%, and the defects density of less than 0.5%. The material wastage is minimized by up to 25%. Moreover, self-healing efficiency in closure is more than 60% as well. This integrated method significantly enhances performance, accuracy, and sustainability in modular construction and thus provides a transforming solution for the infrastructure development process.