Topology Optimization with Experimental-Numerical Investigation of 3D-Printed Concrete Elements (2025-12)¶

Introducing a new era in construction, three-dimensional concrete printing (3DCP) merges sustainability with geometrically sophisticated structural (Architectural) liberty. Despite its exciting potential, optimizing structural topology and material composition for mechanical performance and printability is a big scientific challenge. This research addresses the influence of topology optimization and sustainable mix design on the structural behavior of 3D-printed concrete (3DCP) elements through a combined experimental–numerical approach. A novel eco-efficient cementitious mixture, free of chemical admixtures and incorporating fly ash and ground granulated blast-furnace slag (GGBS) at a binder-to-fine aggregate ratio of 1:1.25, was developed with excellent rheological and printability characteristics. Seven topological configurations ArchN, Triangular, Triangle, Lattice, and Hexagonal were analysed using finite element simulations in Abaqus CAE to evaluate stress distribution, deformation, and load capacity. Two models, Truss and Triangular, were then printed using the TVASTA Nirmaan printer and experimentally tested under conditions replicating the simulations. The numerical and experimental results showed close agreement, with an average deviation of 2.3 %, validating the accuracy of the modeling framework. The triangular topology exhibited superior performance due to its efficient stress transfer and geometric stability. This study establishes a foundation for sustainable, performance driven 3DCP design, promoting material efficiency and eco-friendly construction practices.