UNM Engineers Develop Bendable Concrete for 3D Printing

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Are You Ready for a Revolution in 3D Printing?

Imagine a world where buildings and bridges are constructed with a type of concrete that can bend and flex without breaking. Sounds like science fiction, right? But a team of engineers at the University of New Mexico (UNM) has made it a reality with their patented bendable concrete designed for 3D printing.

The team, led by Maryam Hojati, assistant professor in UNM’s Gerald May Department of Civil, Construction, and Environmental Engineering, aimed to address the brittleness, high labor costs, and dangers associated with traditional building methods. After years of research and experimentation, they have developed a revolutionary material that may change the face of construction forever.

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The Problem with Traditional Concrete

Traditional concrete is renowned for its strength under compression, but it’s inherently brittle, leading to frequent cracks and the need for regular maintenance in infrastructure such as sidewalks and bridges. This limitation has been a primary motivation for the UNM team’s research. “Concrete by itself does not show any tensile properties,” Hojati explained.

Traditional Concrete	Limitations
Strong under compression	Brittle, prone to cracking
Low cost	Requires regular maintenance
Wide availability	Limited tensile properties

The Solution: Self-Reinforced Ultra-Ductile Cementitious Material

The UNM team has developed a composite material, classified as self-reinforced ultra-ductile cementitious material, which can withstand both bending and tensile forces without fracturing. By incorporating short polymer fibers into the concrete mix, the material achieves a unique balance of strength and flexibility.

Graduate researcher Muhammad Saeed Zafar, who completed his Ph.D. in summer 2024, played a pivotal role in developing the material. “If we can successfully design ultrahigh ductile material without using conventional steel bars, it will solve the problem of the incompatibility of reinforcement with the 3D printing process,” he stated.

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How Does it Work?

The development process involved meticulous experimentation with various fibers and additives, including polyvinyl alcohol, fly ash, silica fume, and ultra-high molecular weight polyethylene fibers. The team sought to find the optimal balance where the material could flow through a 3D printing nozzle without clogging while retaining enough fiber to prevent the printed structure from collapsing.

After numerous trials, the team successfully created four different mixes that offer up to an 11.9% increase in strain capacity. The material’s performance is a significant improvement over traditional concrete, which typically has a strain capacity of around 0.1%.

Mix Number	Strain Capacity Increase
Mix 1	5.5%
Mix 2	7.2%
Mix 3	9.5%
Mix 4	11.9%

The Future of Construction

The development of this bendable concrete has far-reaching implications for the construction industry. With the ability to create structures that can bend and flex, architects and engineers can design buildings that are more resilient and sustainable. The material’s potential to minimize the requirement of external reinforcement also means that construction projects can be completed faster and with lower labor costs.

As Hojati noted, “If we use this material at a larger scale, we can minimize the requirement of external reinforcement to the printed concrete structure.” This could lead to a revolution in the way we build, with a focus on creating structures that are not only stronger but also more sustainable and environmentally friendly.

Parallel Advancements in 3D Printing Construction

The development of bendable concrete is not the only innovation in 3D printing construction. Researchers at ETH Zurich have introduced Impact Printing, a robotic construction technique that utilizes Earth-based materials like sand, clay, and gravel. This method reduces carbon emissions by eliminating the need for cement and relies on locally sourced, recyclable materials.

Similarly, the University of Virginia (UVA) has made strides in enhancing the sustainability of 3D printed concrete. UVA researchers developed a cementitious composite by incorporating graphene nanoplatelets (GNPs) with limestone-calcined clay (LC2). The team found that adding just 0.05% GNPs by weight increased the compressive strength by 23% and reduced greenhouse gas emissions by nearly 31% compared to traditional cement mixtures.

These advancements demonstrate the growing emphasis on sustainability in the 3D printing construction industry. As researchers continue to push the boundaries of what is possible, we can expect to see more innovative materials and techniques that prioritize environmental sustainability and reduce the carbon footprint of construction projects.

Conclusion

The development of bendable concrete for 3D printing is a significant milestone in the construction industry. With its unique combination of strength and flexibility, this material has the potential to revolutionize the way we build. As researchers continue to innovate and push the boundaries of what is possible, we can expect to see more sustainable, resilient, and environmentally friendly structures that benefit both people and the planet.

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