Additive manufacturing (AM), also referred as 3D printing, is a technology that enables building automated three-dimensional objects in a layer-by-layer manner. AM of cement-based and alkali-activated composites has gathered attention over the last decade and is one of the most rapidly developing civil engineering fields. Development of proper mixture compositions which are suitable in fresh and hardened state is one of the key challenges of AM technology in construction. As the behaviour of cement-based materials (CBM) and alkali-activated materials (AAM) is determined by chemical and physical processes at the nano-level, incorporation of nano- and micro-sized admixtures has great influence on the performance of printable composites. These modifications are attributed to the unique reactivity of nanoparticles associated with their small size and large surface area. This review paper summarizes recent developments in the application of nano- and micro-particles on 3D printable cementitious composites and how they influence the performance of 3D-printed construction materials. The research progress on nano-engineered CBM and AAM is reviewed from the view of fresh and hardened properties. Moreover, comparison between nano- and micro-sized admixtures including nanosilica, graphene-based materials, and clay nanoparticles as well as chemical admixtures such as viscosity-modifying admixtures and superplasticizers is presented. Finally, the existing problems in current research and future perspectives are summarized. This review provides useful recommendations toward the significant influence of nano- and micro-sized admixtures on the performance of 3D printable CBMs.

This paper explores the new potential strategy of using fine recycled aggregates (fRA) derived from waste 3D printed concrete (3DPC) as a substitute for cement in additive manufacturing. This study hypothesizes that fRA can optimize mixture design, reduce cement content, and contribute to sustainable construction practices. Experimental programs were conducted to evaluate the fresh and hardened properties, printability window, and buildability of 3DPC mixes containing fRA. Mixes with replacement rates of cement with fRA by 10 vol%, 20 vol%, 30 vol%, 40 vol%, and 50 vol% were produced. A comprehensive experimental protocol consisting of rheological studies (static and dynamic yield stress), dynamic elastic modulus determination (first 24 h of hydration), flexural and compressive strengths (2 d and 28 d), and an open porosity test was performed. The obtained results were verified by printing tests. In addition, an economic and environmental life cycle assessment (LCA) of the mixes was performed. The results indicate that up to 50 vol% cement replacement with fRA is feasible, albeit with some technical drawbacks. While fRA incorporation enhances sustainability by reducing CO₂ emissions and material costs, it adversely affects the printability window, green strength, setting time, and mechanical properties, particularly in the initial curing stages. Therefore, with higher replacement rates (above 20 vol%), potential optimization efforts are needed to mitigate drawbacks such as reduced green strength and buildability. Notably, replacement rates of up to 20 vol% can be successfully used without compromising the overall material properties or altering the mixture design. The LCA analysis shows that reducing the cement content and increasing the fRA addition results in a significant reduction in mix cost (up to 24%) and a substantial decrease in equivalent CO₂ emissions (up to 48%). In conclusion, this study underscores the potential of fRA as a sustainable alternative to cement in 3D printed concrete.

The impact of extra-low dosage (0.01% by weight of cement) Graphene Oxide (GO) on the properties of fresh and hardened nanocomposites was assessed. The use of a minimum amount of 2-D nanofiller would minimize costs and sustainability issues, therefore encouraging the market uptake of nanoengineered cement-based materials. GO was characterized by X-ray Photoelectron Spectroscopy (XPS), Fourier-transform infrared spectroscopy (FTIR), Atomic Force Microscopy (AFM), X-ray Diffraction (XRD), and Raman spectroscopy. GO consisted of stacked sheets up to 600 nm × 800 nm wide and 2 nm thick, oxygen content 31 at%. The impact of GO on the fresh admixtures was evaluated by rheology, flowability, and workability measurements. GO-modified samples were characterized by density measurements, Scanning Electron Microscopy (SEM) analysis, and compression and bending tests. Permeability was investigated using the boiling-water saturation technique, salt ponding test, and Initial Surface Absorption Test (ISAT). At 28 days, GO-nanocomposite exhibited increased density (+14%), improved compressive and flexural strength (+29% and +13%, respectively), and decreased permeability compared to the control sample. The strengthening effect dominated over the adverse effects associated with the worsening of the fresh properties; reduced permeability was mainly attributed to the refining of the pore network induced by the presence of GO.