Additive Reinforced Concrete for Multifunctional Construction Component (2025-11)¶

Achieving multifunctional structures in construction often requires embedding functional materials into cement-based mortars before additive manufacturing or applying functional layers after solidification. However, these approaches face challenges such as uneven material distribution and mechanical mismatches. Here, the additive reinforced concrete (ARC) manufacturing process, which integrates the end effectors of both fused filament fabrication (FFF) with cement-based mortar extrusion printing (CEP), is presented. This hybrid approach enables the simultaneous deposition of cement-based mortar and fused polymeric filament, with different nozzle configurations allowing the filament to be deposited outside, inside, or sandwiched within the concrete. The ARC manufacturing process facilitates embedding diverse functional components, such as polymers, into freeform 3D printed concrete (i.e., 3D printable cement-based mortars) structures for applications in thermal insulation. Polymeric materials significantly enhance thermal insulation compared to pure mortar, with the performance of polylactic acid (PLA) and polyethylene terephthalate glycol (PETG) evaluated in various configurations within the concrete. This work establishes a scalable pathway for multifunctional concrete structures, advancing innovative and efficient building solutions.