A Novel and Flexible Approach to Modeling the Additive Manufacturing Extrusion of Cementitious Materials (2025-08)¶

This paper presents a novel approach to model the additive manufacturing (AM) of cementitious materials using Computational Fluid Dynamics simulations. With the construction industry increasingly adopting 3D printing technologies for the manufacturing of cementitious structures, there is a pressing need for innovative solutions that can enhance sustainability, reduce costs, and improve efficiency. Traditional construction methods, which heavily rely on manual labor and conventional manufacturing techniques, are being challenged by the capabilities of 3D printing to produce complex geometries with minimal waste and reduced environmental impact. The computational approach utilizes OpenFOAM, an open-source computational library, to develop and validate a simulation framework for the extrusion-based 3D printing process. Through a series of case studies, we demonstrate the accuracy and flexibility of our method in predicting the behavior of cementitious materials during the printing process. Key findings highlight the potential of our approach to optimize printing parameters, improve structural integrity, and enable the creation of intricate designs that were previously unfeasible. This study contributes to the body of knowledge by providing a comprehensive understanding of the flow behavior of cementitious materials in 3D printing applications and opens new avenues for future research and development in the field of sustainable construction.