Development of a novel 3D construction printer for consistent buildability of novel geopolymer mortar and its challenges

This study focuses on the development of a 3D construction printer and the challenges encountered during its design and implementation. Unlike traditional 3D printers, which are typically used for small-scale parts, this construction printer is specifically designed to handle the demands of large-scale building projects. The printer includes a robust print bed and advanced mechanical and electrical components to ensure precision and stability during the printing process. Significant modifications were made to address key issues such as instability and inconsistent material extrusion. These included adding a second rail on the y-axis for enhanced stability, upgrading the electric motor to a more powerful version, and replacing the gearbox with a higher ratio (1:50) for better control. Additionally, the helical rod was upgraded from a 10 mm to a 20 mm diameter to prevent bending, and the aluminum cylinder was replaced with a transparent plastic one to allow for real-time monitoring and detection of air gaps. The experimental design highlights the challenges faced while printing large-scale objects, with a focus on optimizing process parameters for successful construction printing. Issues such as maintaining consistent extrusion flow, ensuring proper layer adhesion, and controlling temperature variations were addressed through iterative testing and adjustments. The developed 3D construction printer demonstrates significant potential for the construction industry, offering new possibilities for automation and precision in building processes. The improvements and key design specifications validated through experimental results underscore the printer’s capability to produce high-quality, structurally sound components, thus contributing to the advancement of additive manufacturing in construction.