Stress-Informed Non-Planar Slicing for 3D Concrete Printing (2025-10)¶

Stress-Informed Non-Planar (SINP) slicing represents a transformative approach to enhancing the structural efficiency of 3D-printed concrete (3DPC) elements by aligning layer deposition paths with principal stress patterns. Computational stress analysis allows for optimising layer geometry, improving strength-to-weight ratios and achieving targeted mechanical grades. Finite element analysis maps stress trajectories under pre-defined loads, guiding the generation of non-planar toolpaths to reinforce highstressed regions. Building on the preliminary material benchmarking conducted in our robotic 3D Concrete Printing (3DCP) lab, this paper demonstrates how it is possible to capitalise on the anisotropic 3DPC behaviour by aligning layer orientation to principal stresses, by presenting the implementation of SINP slicing of a structural 3DPC element. By harmonising computational design with empirical material insights, stress-informed slicing advances 3DCP towards load-adaptive, resource-efficient structural systems, setting a precedent for scalable adoption in construction.