Advancements in Additive Manufacturing for 3D-printed Mortar-Based Concrete Houses: Technical Analysis for Large-Scale Construction

The advent of 3D printing mortar technology heralds a transformative era in construction, offering a superior alternative to traditional methods in terms of efficiency, cost-effectiveness, and speed. This groundbreaking technology seamlessly integrates three-dimensional computer design, computer-aided design (CAD), rapid prototyping, and mechatronic components to enable the creation of structures through additive manufacturing. Additive manufacturing's layer-by-layer approach allows the precise realization of complex geometric designs. 3D mortar printing technology revolutionizes engineering practices by facilitating safer construction processes, reducing costs, and accelerating construction. The end products of 3D mortar printing exhibit exceptional precision, accuracy, and the capacity to realize intricate architectural designs. A significant milestone in developing 3D printing technology for construction was achieved by Behrokh Khosnevis in 2004 with the introduction of contour crafting (CC). As Indonesia experiences population growth and increased human capital, the demand for rapid construction solutions escalates. This paper conducts a technical analysis focused on the application of additive manufacturing to create 3D-printed concrete houses utilizing mortar-based materials. The analysis delves into civil engineering challenges tied to mortar research for 3D-printed concrete houses, encompassing aspects such as 3D mortar printing concepts, general mix designs, 3D printing machine architecture, and an array of testing procedures, including assessments of flowability, rheology, extrudability, and buildability. The laboratory-scale 3D printing machine employed in this study features a parallel manipulator with a gantry boasting three axes (X, Y, and Z). This prototype exhibits significant potential for scaling up to meet the requirements of large-scale construction projects. Ongoing enhancements to the machine encompass mechanical improvements, incorporating advanced sensor systems, optimization, and augmentations in machine capacity. In conclusion, this research endeavors to shed light on the technical intricacies of 3D mortar printing for construction applications, with a particular emphasis on mix design, machine development, and performance testing.