Parameter Tuning for Sustainable 3D Printing (3DP) of Clay Structures

Abstract

Due to high carbon emissions, traditional construction methods are often costly, resource-intensive, and environmentally harmful. This study investigates the potential of additive manufacturing (AM) or 3D printing (3DP) using earthen clay as a sustainable alternative for building structures. Despite its promising benefits, challenges such as water/clay ratio, nozzle clogging, and temperature variations hinder widespread adoption. Employing the design of experiment (DOE) approach, this research systematically optimizes 3DP parameters, including nozzle diameter, layer height, infill percentage, and printing speed, using commercial earthen clay. Chemical compositions are analyzed using X-ray photoelectron spectroscopy (XPS) and energy-dispersive spectroscopy (EDS). Quantitative analysis compares measured dimensions of 3DP structures to assess dimensional accuracy, while buildability assessments explore structural integrity. Results indicate that lower layer heights generally enhance dimensional accuracy, with larger nozzle diameters enabling faster printing speeds. ANOVA analysis reveals significant relationships between printing parameters and dimensional outcomes, emphasizing the importance of 3DP process parameters selection. Optimal printing parameters lead to high-quality prints, although with limitations in scalability. This research contributes valuable insights for stakeholders seeking sustainable 3DP practices in construction, paving the way for more environmentally friendly and cost-effective building solutions.