Design of Porous Structures in 3D Concrete Printing Using Procedural Print Patterns (2025-03)¶

3D Concrete Printing (3DCP) enables the manufacturing of complex structures without increasing the costs of the process. However, this increased complexity is limited by conventional design workflows based on boundary representation 3D modelling and conventional slicing methods. While previous research has demonstrated the potential of print paths as a design method for customised structures and surface qualities, their use to generate controlled porosity in 3DCP structures is still unexplored. This paper investigates the use of print patterns at the scale of the printed filament to control the porosity, material distribution, and surface area of 3DPC structures, creating variable porosity and permeability that enhance design flexibility in 3DCP. For this, seven printing patterns were developed and tested to assess the relationship between exposed surface area and material use. The findings demonstrated that alternating patterns could create permeable structures with an extended surface area, which enables the creation of multi-functional structures. This research contributes to extending the design possibilities of 3DCP, allowing the generation of material properties that can be embedded and graded throughout the printed part.