Numerical simulation of the extrusion and layer deposition processes in 3D concrete printing with the Particle Finite Element Method

3D Concrete Printing (3DCP) is a rapidly evolving technology that allows for the efficient and accurate construction of complex concrete objects. In this paper, a numerical modelling approach is presented for the simulation of the printing process of cementitious materials, based on the homogeneous fluid assumption. To cope with the large deformations of the domain and the nonlinearity resulting from the use of a non-Newtonian rheological law, the Navier–Stokes equations are solved in the framework of the Particle Finite Element Method (PFEM). Furthermore, tailored solutions have been formulated and implemented for the time-dependent moving boundary conditions at the nozzle outlet and for the efficient handling of the inter-layer contact in the same PFEM framework. The overall computational cost is decreased by the implementation of an adaptive de-refinement technique, which drastically reduces the number of degrees of freedom in time. The proposed modelling approach is finally validated by simulating the printing process of six rectilinear layers and one multi-layer “wall”. The results show good agreement with the experimental data and provide valuable insights into the printing process, paving the way for the use of numerical modelling tools for the optimization of materials and processes in the field of 3D Concrete Printing.