3D Printing of Polymers with Continuous Fibers to Replace Steel Reinforcement and Structural Steel in Construction

Abstract

Three dimensional (3D) printing technology has the potential for reshaping the construction industry. Despite advances in 3D concrete printing, the majority of construction applications still require structural steel or steel reinforcement in order to achieve code compliance. Development of polymer-based high-filled composite with a fiber reinforcement can be a better alternative to the cementitious composite for 3D printing while providing better strength and durability. These materials can be used in various civil engineering applications, including slab on grades, precast architectural panels, facade construction, and more. The current paper gives a first insight into the application of the newly developed polymer-based composite and 3D printing technology, combining composite extrusion, ultraviolet curing, and continuous glass fiber reinforcement. In this case, the fiber, which has been saturated with the organic binder, is laid out layer by layer on top of the extruded layer of the composite. Thus, the high adhesion between the matrix and the fiber is achieved. This study presents the current capabilities of 3D-printed structures with continuous fibers to eliminate steel reinforcement and structural steel in residential buildings. Advantages of the developed 3D printing technology amidst 3D concrete printing are described. The study also provides methods to evaluate the strength and durability of 3D-printed structures.