Powder-Bed 3D Printing of Cementitious Materials for Lightweight Construction Elements (2024-09)¶

The aim of this work is the process engineering of additive manufacturing using powder bed technology for the customised production of optimised, structurally complex lightweight elements that are to be used in the construction sector. The powder bed technology ensures almost complete freedom of shaping with the loss-free use of dry mortar powder, making the optimised design practically feasible. Optimisation of material and technology for 3D powder bed printing will be discussed in terms of overall porosity, particle and pore size, flowability, pourability, bulk density and wettability of the powder used, as well as the type and speed of recoater, amount of activator solution and droplet size and flow rate of the activator solution. Strength of printed samples for handling, shape accuracy and final strength after hardening are considered as governing parameters for the material and process optimization.