Voxel-based path-driven 3D concrete printing process simulation framework embedding interlayer behavior

This paper introduces a numerical framework to model the 3D concrete printing process, considering critical factors, particularly the print path and interlayer interactions. Within this framework, a finite element model is automatically generated for an arbitrary 3D-printed object. This is achieved by voxelizing the bounding space, incorporating a zero-thickness interlayer cohesive zone, and pinpointing the active elements. Additionally, a print path-driven element segment algorithm is developed, allowing for sequential element placement in alignment with the print path during simulation, thereby mirroring the actual printing process. The model efficacy is demonstrated through two benchmarks, focusing on elastic buckling and plastic failure, where it agrees with existing experimental and numerical data. Using this validated model, the impacts of various printing parameters, such as print width, speed, path, and interlayer behaviors are explored, and an integrated toolbox for both educational and academic purposes is created. This toolbox is available at https://github.com/Baixi-Chen/3DCPProcessSimulaion.git.