Nowadays, one very dynamic development of 3D printing technology is required in the construction industry. However, the full implementation of this technology requires the optimization of the entire process, starting from the design of printing ideas, and ending with the development and implementation of new materials. The article presents, for the first time, the development of hybrid materials based on a geopolymer or ordinary Portland cement matrix that can be used for various 3D concrete-printing methods. Raw materials used in the research were defined by particle size distribution, specific surface area, morphology by scanning electron microscopy, X-ray diffraction, thermal analysis, radioactivity tests, X-ray fluorescence, Fourier transform infrared spectroscopy and leaching. The geopolymers, concrete, and hybrid samples were described according to compressive strength, flexural strength, and abrasion resistance. The study also evaluates the influence of the liquid-to-solid ratio on the properties of geopolymers, based on fly ash (FA) and metakaolin (MK). Printing tests of the analyzed mixtures were also carried out and their suitability for various applications related to 3D printing technology was assessed. Geopolymers and hybrids based on a geopolymer matrix with the addition of 5% cement resulted in the final materials behaving similarly to a non-Newtonian fluid. Without additional treatments, this type of material can be successfully used to fill the molds. The hybrid materials based on cement with a 5% addition of geopolymer, based on both FA and MK, enabled precise detail printing.

Three-dimensional concrete printing (3DCP) is an innovative technology that can lead to breakthrough modifications of production processes in the construction industry. The paper presents for the first time the possibility of 3D printing concrete–geopolymer hybrids reinforced with aramid roving. Reference concrete samples and concrete–geopolymer hybrids composed of 95% concrete and 5% geopolymer based on fly ash or metakaolin were produced. The properties of the samples without reinforcement and samples with 0.5% (wt.) aramid roving were compared. The frost resistance tests, UV radiation resistance, and thermal conductivity were evaluated for samples that were 3D-printed or produced by the conventional casting method. Compressive strength tests were carried out for each sample exposed to freeze–thaw cycles and UV radiation. It was observed that after the frost resistance test, the samples produced by the 3D printing technology had a minor decrease in strength properties compared to the samples made by casting. Moreover, the thermal conductivity coefficient was higher for concrete–geopolymer hybrids than concrete reinforced with aramid roving.

The intensive development of 3D Concrete Printing (3DCP) technology causes constantly increased its share in the construction sector. However, in order to produce products with controlled properties, optimization of the technological process is still required. Automation of production based on additive manufacturing methods streamlines the process by comprehensively manufacturing building components that meet, among others, strength, visual, and insulation requirements. Moreover, the possibility of using computer simulations to assess the properties of the designed elements allows for a multitude of analyzed versions of the constructed partitions, which can be verified at the design stage. Thanks to such an opportunity, the process of designing building elements can be significantly improved. The article presents results related to the assessment of the level of thermal insulation of products that can be produced by additive technology, depending on the applied spatial geometry of the vertical partition and the amount and type of materials used. Eight original solutions of in-fill pattern were designed, for which both Finite Element Method (FEM) computer simulations of thermal conductivity and experimental measurements of thermal conductivity of samples were performed. On the basis of the obtained results, both the correctness of the simulation results for the various analyzed materials and their consistency with the practical results were found. Depending on the investigated geometry, for samples of the same dimensions and using the same material, the differences in the U-factor obtained by FEM analysis amounted to 61%. The best solution from the investigated spatial geometries of the vertical partitions has been indicated. The U parameter in the variant with the best thermal insulation was 0.183 W/m²K, which meets the requirements of Polish construction law. The issues discussed in this work can be the basis for the selection of the best solution possible for practical use during the production of building walls using the 3DCP method fulfilling the guidelines of applicable standards. Furthermore, they can be used as a tool for optimizing geometry in terms of energy savings and reducing waste production by both engineers developing 3DCP technologies and architects using innovative techniques for manufacturing building structures.

Recent years have witnessed a growing global interest in 3D concrete printing technology due to its economic and scientific advantages. The application of foamed concrete, renowned for its exceptional thermal and acoustic insulation properties, not only holds economic attractiveness but also aligns seamlessly with the principles of sustainable development. This study explores various solutions related to 3D printing technology in construction, discussing the design, production, and properties of foamed concrete mixtures. The integration of 3D printing and the potential for automating the entire process offers opportunities to boost productivity and reduce construction costs. Furthermore, the utilization of foamed concrete with its commendable insulation properties will enable a reduction in the usage of materials other than concrete (e.g., mineral wool, facade mesh, and polystyrene), significantly facilitating the recycling process during building demolition. This, in turn, will lead to the preservation of nonrenewable natural resources and a decrease in CO₂ emissions. Despite the promising results, there have been limited studies focusing on 3D printing with foamed materials, whereas a survey of the existing body of literature indicates a notable absence of endeavors pertaining to the utilization of aerated concrete within the realm of 3D printing, especially geopolymer composites (GP) and hybrid geopolymer composites (HGP). The outcomes delineated in the ensuing discourse are demonstrative for conventionally used materials rather than the additive manufacturing variant. Hence, this work aims to systematically review existing practices and techniques related to producing foamed concrete with 3D printing technology. This analysis also contributes to the establishment of a foundational framework and furnishes a preliminary basis upon which future endeavors aimed at the 3D printing of aerated concrete can be embarked. The findings from the literature analysis justify the desirability of continuing research on this topic, particularly when considering the potential for large-scale industrial implementation. This article provides a comprehensive state of the knowledge on the development of 3D printing techniques for foamed concrete mixtures. By consolidating and analyzing findings from different studies, this article offers insights into the advancements, challenges, and potential applications of foamed concrete in additive manufacturing processes. This, in turn, contributes to the overall understanding and advancement of 3D printing technologies using foamed concrete as a versatile and sustainable construction material. The encouraging results obtained from the analysis further underscore the need for the continued exploration of 3D printing, especially with an eye towards its industrial-scale implementation.

The continued global urbanization of the world is driving the development of the construction industry. In order to protect the environment, intensive research has been carried out in recent years on the development of sustainable materials and ecological construction methods. Scientific research often focuses on developing building materials that are renewable, energy-efficient, and have minimal impact on the environment throughout their life cycle. Therefore, this article presents research results aimed at developing a concrete mixture using cement with reduced CO₂ emissions. In the context of increasing ecological awareness and in line with European Union policy, the development of a mixture based on environmentally friendly cement is of key importance for the future development of the construction industry. The article compares the physical properties of two mixtures, their foaming possibilities, and the influence of the added polypropylene (PP) fibers on the strength properties of the produced composites. It was found that bending strength and compressive strength were highest in the material with silica fume and aluminum powder at 5.36 MPa and 28.76 MPa, respectively. Microscopic analysis revealed significant pore structure differences, with aluminum foamed samples having regular pores and hydrogen peroxide foamed samples having irregular pores. Optimizing aluminum powder and water content improved the materials’ strength, crucial for maintaining usability and achieving effective 3D printing. The obtained results are important in the development of research focused on the optimization of 3D printing technology using concrete.

In the face of accelerating urbanization and the growing demand for environmentally responsible materials and designs, this study presents the development and implementation of a modular parklet demonstrator fabricated using dual-material 3D printing. The structure integrates polylactic acid (PLA) and wood-filled PLA (wood/PLA), combining the mechanical robustness of pure PLA in the core with the tactile and aesthetic appeal of wood-based biocomposite on the surface. The newly developed dual-nozzle 3D printing approach enabled precise spatial control over material distribution, optimizing both structural integrity and sustainability. A comprehensive evaluation was conducted for developed filaments and printed materials, including optical microscopy, coupled thermogravimetry analysis and Fourier Transform Infrared Spectroscopy (TG/FTIR), differential scanning calorimetry (DSC), and chemical and mechanical resistance testing. Results revealed distinct thermal behaviors and degradation pathways between filaments and printed parts composed of PLA and PLA/wood. The biocomposite exhibited slightly increased sensitivity to aggressive chemical environments and mechanical wear, dual-material prints maintained high thermal stability and interlayer adhesion. The 3D-printed demonstrator bench and stools were successfully deployed in public spaces as a functional urban intervention. This work demonstrates the feasibility and advantages of using biocomposite materials and dual-head 3D printing for the rapid, local, and sustainable fabrication of small-scale urban infrastructure.