Stress Transfer Research Articles

One-Component polyurethane adhesive filled with milled carbon fibre and its effect on hydrothermal stability of beech-glued joints

ABSTRACT The effect of fibres of various lengths, thicknesses, origins, and quantities on mechanical and other properties of polymer matrices is well-known, including carbon fibres. These were used in the form of milled carbon fibres (MCF) to fill a one-component polyurethane (1C-PUR) commercial adhesive to determine hydrothermal resistance of beech-bonded joints tested in shear. The effect of MCF (1%, 3%, 5%, and 7%) was first tested on thin adhesive films before and after exposure to cold water (20°C) and boiling (wet state test and after drying). A good bond of 1C-PUR to MCF was demonstrated, with tensile mechanical properties significantly increased after the addition of 3% and 5% MCF in all tested environments. The aqueous environment, especially boiling water, led to a deterioration in mechanical properties, but after drying, there was a recovery and, in many composite films, an improvement. This was due to a change in adhesive’s domain structure, as demonstrated by differential scanning calorimetry. An increase in hydrothermal resistance of glued wood joints with MCF (1%, 3%, and 5%) was not demonstrated based on tensile shear strength. However, considering the achieved wood failure, it was proven that MCF has a positive effect on stress transfer into the wood adherend.

Poly(ethylene-co-(acrylic acid)) and maleic anhydride effect on micro crystalline cellulose and lignin-filled EPDM automotive sealing profiles.

In this study, the effect of Poly(ethylene-co-(acrylic acid)) and maleic anhydride on cellulose and lignin-filled EPDM elastomers was investigated. Poly(ethylene-co-(acrylic acid)) and maleic anhydride were added in certain amounts (3.5 phr) to determine their chemical, thermal, rheological, mechanical, and morphological properties. With the addition of Poly(ethylene-co-(acrylic acid)) and maleic anhydride, higher thermal stability and slower vulcanization with retarded ts2 and t90 were seen. Improved elongation and tear strength were also observed. However, maleic anhydride-added cellulose and lignin-filled EPDM had a higher tensile strength value since it formed adequate chain mobility and had good interfacial compatibility that made stress transfer easy. Despite some immiscibility phases (especially after maleic anhydride) and microvoid structures, no considerable aggregation was observed in all elastomers. In conclusion, Poly(ethylene-co-(acrylic acid)) and maleic anhydride on cellulose and lignin-filled EPDM elastomers can be recommended for mechanical, rheological, and ecological benefit to industries that are interested in biopolymer-filled EPDM elastomers.

Concrete members strengthened by adhesive-bolted steel plates: shear behaviour of the composite connection interface

The method of strengthening adhesive-bolted steel plates is widely used in various strengthening projects due to its advantages of slight damage to the original structure, convenient construction, and wide application. However, the strengthening effect is greatly limited by the stripping failure of the steel-adhesive-concrete interface. Some researchers have studied the shear behaviour of the anchor bolts and adhesive layer on the interface. While developing an accurate model to predict the behaviour of the hybrid connection interface is still a large challenge. In this paper, shear tests were carried out on push-out test specimens with three different interface connection forms to investigate the failure mechanism of the adhesive-bolted steel plate composite connection interface. The failure process and failure mode of various interfaces were summarized. Moreover, the ultimate strength, load vs. slips curve, interface strain, and stiffness degradation were discussed. The obtained results indicate that anchor bolts could limit the transfer of interfacial shear stress, and the interface with a larger anchor bolt diameter possesses better plasticity, greater average stiffness, and could bear a high shear force after multiple stripping. The interfacial ultimate shear capacity depends on the relative strength of the anchor bolts and adhesive layer. For the interface with lower strength anchor bolts, the interface strength depends on the strength of the adhesive layer. For the interface with higher strength anchor bolts, the interface strength depends on the anchor bolts and the area of the unpeeled adhesive layer before the failure of the interface. Subsequently, the design method for estimating the shear strength of the interface with sufficient efficiency was proposed based on the data analysis.

Construction of nanocomposite interphase with controllable thickness to relieve stress concentration and boost stress transfer from carbon fiber/epoxy resin interface

Construction of nanocomposite interphase with controllable thickness to relieve stress concentration and boost stress transfer from carbon fiber/epoxy resin interface

Visualizing fiber end geometry effects on stress distribution in composites using mechanophores.

Localized stress concentrations at fiber ends in short fiber-reinforced polymer composites (SFRCs) significantly affect their mechanical properties. Our research targets these stress concentrations by embedding nitro-spiropyran (SPN) mechanophores into the polymer matrix. SPN mechanophores change color under mechanical stress, allowing us to visualize and quantify stress distributions at the fiber ends. We utilize glass fibers as the reinforcing material and employ confocal fluorescence microscopy to detect color changes in the SPN mechanophores, providing real-time insights into the stress distribution. By combining this mechanophore-based stress sensing with finite element analysis (FEA), we evaluate localized stresses that develop during a single fiber pull-out test near different fiber end geometries-flat, cone, round, and sharp. This method precisely quantifies stress distributions for each fiber end geometry. The mechanophore activation intensity varies with fiber end geometry and pull-out displacement. Our results indicate that round fiber ends exhibit more gradual stress transfer into the matrix, promoting effective stress distribution. Also, different fiber end geometries lead to distinct failure mechanisms. These findings demonstrate that fiber end geometry plays a crucial role in stress distribution management, critical for optimizing composite design and enhancing the reliability of SFRCs in practical applications. By integrating mechanophores for real-time stress visualization, we can accurately map quantified stress distributions that arise during loading and identify failure mechanisms in polymer composites, offering a comprehensive approach to enhancing their durability and performance.

Carbon nanotubes at bilayer in-plane graphene/hBN with interlayer twist angles abnormally enhance its interlayer stress transfer.

A possibility of unprecedented architecture may be opened up by combining both vertical and in-plane heterostructures. It is fascinating to discover that the interlayer stress transfer, interlayer binding energy, and interlayer shear stress of bi-layer Gr/hBN with CNTs heterostructures greatly increase (more than 2 times) with increase the numbers of CNTs and both saturate at the numbers of CNTs= 3, but it causes only 10.92% decrease in failure strain. By analyzing the crack propagations and Von-Mises stress, we find that this abnormal enhancement in interlayer stress transfer and toughness originates from the localization of the stress fields arising from misfit dislocations and their out-of-plane deformations at the joints of CNTs and B-Gr/hBN heterostructures. Our discoveries hold great importance in comprehending the mechanical interfacial characteristics of bi-layer Gr/hBN and are anticipated to spark a great deal of curiosity in investigating its novel physics and potential uses.

Superelastic bamboo cellulose nanofiber based carbon aerogel with layered network microstructure for high sensitivity piezoresistive sensor.

Carbon aerogels, characterized by their high porosity and superior electrical performance, present significant potential for the development of highly sensitive pressure sensors. However, facile and cost-effective fabrication of biomass-based carbon aerogels that concurrently possess high sensitivity, high elasticity, and excellent fatigue resistance remains a formidable challenge. Herein, a piezoresistive sensor with a layered network microstructure (BCNF-rGO-CS) was successfully fabricated using bamboo nanocellulose fiber (BCNF), chitosan (CS), and graphene oxide (GO) as raw materials. The fabrication process involved directional ice-crystal growth and mild hydrothermal reduction methods where the directional ice-crystal growth technique imparted a stable network-like pore structure, while the mild hydrothermal reduction method ensured electrical conductivity without compromising the original properties of the CNF. Taking advantage of the stress transfer properties of the cross-linked network structure, BCNF-rGO-CS exhibited exceptional reversible compressibility (sustaining 80% strain), high fatigue resistance (10,000cycles at 60% strain), and high stress retention (84.6%) over long-term cycling. Furthermore, the BCNF-rGO-CS sensor exhibited notable low-pressure sensitivity, excellent response time (66/76ms), and it was capable of responding to ultra-low pressures of 10Pa. Based on these favorable characteristics, the piezoresistive sensor holds promising prospects for applications in body motion detection, health monitoring, and flexible electronic-skin.

Material selection for efficient strain transfer in pavement monitoring using FBG sensors

ABSTRACT Fibre Bragg Grating (FBG) sensors are increasingly used to monitor road pavement infrastructures due to their sensitivity and resilience. However, challenges such as mechanical vulnerability and effective strain and stress transfer remain critical. This study addresses these challenges by evaluating the effectiveness of four distinct filling materials (bitumen mastic, polymeric resin, polymeric sealant and flexible polymeric sealant) for installing encapsulated FBG sensors in pavement grooves. An innovative laboratory testing methodology was developed to assess the suitability of these materials in ensuring accurate strain transfer and mechanical protection. Specifically, the research involved embedding FBG sensors in fibreglass rods and testing their performance with various filling materials under controlled conditions. Among the tested materials, the polymeric sealant exhibited the best performance, demonstrating only a minimal stiffness reduction of 5% and acceptable fatigue resistance, closely mimicking the behaviour of conventional asphalt mixtures. These findings offer valuable insights into the practical implementation of FBG sensors in pavement structures and highlight the critical importance of selecting appropriate embedding materials to preserve pavement integrity and ensure precise, long-term monitoring.

Enhancement on thermal management and mechanical properties of cellulose nanofiber films through synergistic filler construction and interface optimization

AbstractThis study is aimed at developing composite films with superior thermal management performance in an attempt to solve challenge rising from heat accumulation in modern high‐frequency broadband communication devices. To effectively address the interface thermal resistance (ITR) of graphene nanoplatelets (GNPs) in the composites, cobalt nanoparticles were coated onto edge‐oxidized graphene to in‐situ form a hybrid filler (EGO@Co), which was then uniformly incorporated into the carboxymethyl cellulose nanofiber (c‐CNF) matrix. A vacuum‐assisted filtration was employed to fabricate EGO@Co/c‐CNF thermally conductive multi‐layered composite films. In‐situ growth of heterogeneous structure filler Co helped to extend the thermal paths and optimize the heat transfer networks. The incorporation of edge oxidation was found to facilitate the strong hydrogen bonding interactions between filler and matrix, constructing an efficient three‐dimensional (3D) thermal conduction network, significantly enhancing both heat flux and stress transfer efficiency. After hot‐pressed, the EGO@Co40/c‐CNF films exhibited an outstanding thermal conductivity (λǁ ~ 28.4 W m−1 K−1 and λ⊥ ~ 1.1 W m−1 K−1) in addition to a high tensile strength. The optimization on the thermal filler construction and interface modification have proved to significantly enhance the microstructure and properties of the composite films, which helps to pave the way for practical opportunities in the application of novel thermally conductive materials in the TMMs fields.Highlights Cobalt nanoparticles enhanced thermal conductivity of composites. EGO strengthened filler‐matrix hydrogen bonding. Vacuum‐assisted filtration produced multi‐layered composite films. EGO@Co/c‐CNF films displayed high thermal conductivity. Thermal filler optimization boosted mechanical and thermal properties.

The Role of Nanotechnology in Enhancing the Mechanical Properties of Composite Materials

Nanotechnology has emerged as a transformative approach in the development of composite materials, offering unprecedented enhancements in their mechanical properties. This paper reviews recent advancements in the integration of nanotechnology in composite material design, specifically focusing on the impact of nanoscale reinforcements, such as nanoparticles, nanotubes, and nanofibers, on the mechanical strength, durability, and performance of composites. By embedding these nanoscale additives into traditional composite matrices, researchers have observed significant improvements in tensile strength, modulus of elasticity, and impact resistance, among other mechanical traits. Theoretical perspectives and empirical research are synthesized to explore how nano-scale modifications influence interfacial bonding and stress transfer mechanisms within composites. Special attention is given to the role of nanoparticle dispersion techniques and surface functionalization in optimizing the mechanical enhancements offered by nonreinforcements. Case studies involving carbon nanotubes in aerospace applications, silica nanoparticles in construction materials, and graphene nanosheets in automotive components are examined to illustrate the practical implications and challenges of these advancements. the potential barriers to industrial application, including scalability of production processes, environmental and health safety concerns, and cost-effectiveness of nanomodified composites. The review aims to provide a comprehensive understanding of the scope and limitations of nanotechnology in composite materials, paving the way for future research and application in high-performance engineering domains.

Hierarchical Tough Hydrogel with Enhanced Rigidity and Extensibility for Strain Sensing, Posture Guide, and Injury‐Prevention

AbstractHydrogels, as valuable biomaterials, have limited applications owing to their mechanical fragility. This study presents a structural modification approach to strengthen hydrogels mechanically. First, the precursor hydrogel undergoes deformation through stretching and twisting, resulting in a helical polymer structure and a deformation gradient. This deformed structure is then stabilized by densification and additional crosslinking. The twisted hydrogel shows improved extensibility and toughness owing to enhanced stress transfer in its unique structure. Additionally, multiple hydrogel strands are assembled hierarchically into ropes and cables, exhibiting advantageous mechanical properties such as high energy dissipation and durability. These reinforced mechanical features lead to considerable performance improvements in applications such as strain sensing and impact absorption. Furthermore, practical utility is demonstrated in areas including posture correction and injury prevention. The hydrogel reinforced by this method has the potential to be used in various fields where both mechanical properties and biocompatibility are crucial.

A Method for Calculating the Bearing Capacity of Basic Members of an Underground Concrete-Filled Steel Tube Supporting Arch with a D-Shaped Cross Section

High-strength concrete-filled steel tube (CFST) arches have been widely applied in underground engineering, among which there are special-shaped arches such as D-shaped sections. At present, most studies have concentrated on members with square or circular sections, while relatively few studies have been conducted on D-shaped section members. In this study, firstly, D-shaped sections were initially transformed into sections with a part square and part elliptical shape using an equivalent section method. The formulas for the axial compression and pure bending bearing capacities of the basic D-shaped CFST members were deduced using unified theory, and the bearing capacity of the D-shaped members was calculated in a given case. Secondly, numerical simulations of axial compression and pure bending of the basic CFST members with three section types (square, circular, and D-shaped) were carried out using ABAQUS software. To ensure the reliability of the numerical simulations, the concrete damage constitutive model and the elastic–plastic model were adopted to simulate the core concrete and the steel tube, respectively. In the results, the axial compression and pure bending bearing capacities of the D-shaped section obtained via theoretical calculation were 2339.6 kN and 84.8 kN·m, respectively, while the results obtained via numerical simulation were 2335.8 kN and 85.4 kN·m, respectively, which were relatively close. Among the three section types of members, the D-shaped members had the highest axial compression bearing capacity, which was 1.45% and 4.58% higher than those of the circular and square section members, respectively. However, their bending moment bearing capacity was relatively low. The stress distribution of the D-shaped members presented a characteristic where the circular part dominated, and the stress transfer effect of the members was favorable. In practical engineering, when the surrounding rock pressure is high and evenly distributed, D-shaped section arches can be selected, and increasing the proportion of the square area in D-shaped sections can enhance the overall flexural capacity of arches.

FEA-based Virtual Operation and Stress Distribution Analysis of DHS Screws in Proximal Femoral Bone Fractures: A Strategic Guide for Orthopedic Surgeons in Operational Planning

Background Accidents are the major reasons causing hip bone fractures. These are due to reduced bone density due to aging effect which may cause fractures typically in proximal part of the femur bone. Purpose The purpose of this work is to concentrate on preoperative planning by using a 3D model developed with a virtual operation using a dynamic hip screw (DHS). Methods DHS is generally preferred for the stabilization of stable fractures. The virtual operation was performed on the proximal femoral fracture site, typically for stable fractures. Finite element analysis (FEA) of operated bone was performed to estimate Von Misses stress distribution on the implant post-operatively, resulting in less stress on the fracture site. Results FEA indicates a transfer of stress of the fracture site (35–62%) on the implant, resulting in the operation’s success. Such work will assist orthopedic surgeons in determining load-bearing capacities after the mobilization of the patient. Conclusion Virtual surgery helps the surgeon to identify fracture geometry, the success of the operation, and proper fixation of the implant to avoid post-surgery complications. This aids in the quick recovery of patients, resulting in early rehabilitation.

Study of Asymmetric Face Failure and Limit Support Pressure During Curved Tunnels Excavation in Sandy Soils

ABSTRACTWith the continuous urban development, tunnels are increasingly designed with curved alignments to avoid existing structures and to make better use of the underground space. However, these tunnels are usually subjected to complex forces, and current research on the curved tunnels face stability remains incomplete. This paper presents a detailed face stability analysis of curved tunnels, both analytically and numerically. Initially, a series of 3‐D numerical simulations are performed to investigate the spatially asymmetric failure pattern of the soil ahead of the curved tunnel face and the stress transfer mechanism of the soil arching effect during the excavation process is explored. Subsequently, based on traditional limit equilibrium methods and the results from numerical simulations, an improved wedge‐prism model and corresponding theoretical calculation formulas for the limit support pressure are proposed. The validity of the improved model is confirmed through illustrative analyses, while sensitivity analyses are conducted on the impacts of soil internal friction angle, structural depth ratio, and tunnel curvature radius on the limit support pressure. This study can aid in the calculation of the stability of the tunnel face and the limit support pressure in curved tunnel excavation.

Graphene nanoplatelets inclusion effects on mechanical properties of the hybrid kevlar/basalt fiber reinforced epoxy composites

Abstract This study experimentally examined the effects of hybridizing Basalt and Kevlar fibers on the tensile, and flexural performance of composite materials with the inclusion of Graphene nanoplatelets (GnPs). Various hybrid composites were fabricated, incorporating Basalt and Kevlar fiber composites with 1, 3, and 5 wt% of GnPs as well as without GnPs, as well as hybrid composites featuring different weight content of GnPs reinforcing with with Basalt and Kevlar fibers. The findings of this study indicated that the mechanical properties of epoxy resin were significantly enhanced through the synergistic effects of hybridization with basalt and Kevlar fibers, as well as the incorporation of graphene nanoplatelets (GnPs). The significant increasing in mechanical properties was attributed to the strong interfacial interactions between the epoxy matrix and GnPs nanoparticles, which facilitate improved stress transfer from the fibers and nanoparticles to the matrix. This enhanced stress transfer capability accounts for the superior resistance to fiber pullout observed in composites reinforced with GnPs compared to those without nanoparticles.

Dynamic damage law and failure modes of layered coal-rock mass under impact loading

Abstract Up to now, most of the structural dynamic analysis is based on the Lagrange system, while the Hamilton system is composed of the phase space composed of the generalized displacement and stress, showing a wonderful symmetry, which opens up a new way for the theoretical research and calculation of dynamics. The physical model of the layered combined coal-rock is constructed by dividing the ‘outburst center’ coal in front of the heading face into the combined layered structure. Based on Hamilton mechanics, the Hamilton canonical equation under symplectic geometry structure is established, combined with Hamilton variational principle and symplectic time subdomain method, the multi-layer symplectic element control equation of coal-rock is established, and the dynamic displacement and stress transfer characteristics at any time can be solved by iterative calculation. The action modes of axial torsional stress, radial principal stress and shear stress of layered coal- rock under impact loading are determined, and the weak layer and interlayer stress transfer dynamic response behavior of layered coal- rock under complex stress conditions are determined. The conclusions are as follows: ①Under static loading, the layered shear stress circle provides the initial condition of damage failure, impact loading acts as an exciting force to trigger the torsion effect, forming the ‘ X ’ -shaped shear line in the radial and axial directions of the interlayer interface, and the boundary produces the ‘ V ’ -shaped dynamic spalling surface. ②The short axis is damaged before the long axis, and the central node is the starting point of instability. The main cracks are formed along the long and short axis respectively, and finally the ‘ O-+ ’ failure mode is formed, which verifies the prominent axial and radial spallation phenomenon. This method avoids the non-conservation of system energy caused by energy dissipation, and will become an effective method to study the dynamic mechanical properties and damage evolution path of coal-rock. It has guiding and reference significance for the theoretical research and prevention technology of coal and rock dynamic disasters.

Bio‐Inspired Graded and Uniform Cylindrical Lattices Fabricated by Material Extrusion 3D Printing: An Experimental and Numerical Investigation

ABSTRACTThe main requirements of the biomedical and aerospace industries are new and innovative lightweight materials. Bio‐inspired structures, which are inspired by various biological designs, have demonstrated notable advancements over traditional lightweight structures. In this study, bioinspired uniform and graded cylindrical triply periodic minimal surface (TPMS) and strut‐based lattice structures were studied for their mechanical qualities and energy absorption capacities fabricated by material extrusion 3D printing using PLA material. It was found that the cylindrical TPMS diamond lattice achieved maximum stress of 78.5 MPa and absorbed 19.14 MJ/m3 of energy, outperforming strut‐based designs with a 48% higher energy absorption than cylindrical BCC lattice structure. Graded designs further improve energy absorption through a better stress distribution. The findings validated the Gibson–Ashby model, highlighting the enhanced load distribution and stress transfer in the strut‐based and TPMS diamond structures. The finite element (FE) model results closely matched the experimental data, confirming its predictive reliability with a maximum error of energy absorption of 7.7%, elastic modulus of 6.9%, and plateau stress of 4.7%. These insights underscore the superior energy absorption and mechanical stability of cylindrical TPMS diamond lattices, indicating their potential for satisfying stringent industrial and technical performance requirements. The novelty of these designs lies in their bioinspired structures and significant enhancements in mechanical performance and energy absorption. Future research should build on these results to design efficient materials tailored to specific needs using FE models to optimize development processes before experimental testing.

Synthesis and Characterization of Eco‐Friendly Epoxy Resins and Novel Fillers for Enhanced Corrosion Protection of Mild Steel

ABSTRACTEpoxy resins are often used as protective coatings because of their exceptional adhesion, mechanical strength, chemical resistance, and anticorrosive properties. However, the use of bisphenol A (BPA)‐based epoxies has been linked to environmental and health concerns. The objective of this study was to develop eco‐friendly epoxy coatings for mild steel corrosion protection using bio‐based resorcinol (RESO) and isosorbide (ISO), as well as the development of novel Zn‐Al layered double hydroxide (LDH) and Ce‐bentonite fillers. The epoxy resins were synthesized by reacting resorcinol and isosorbide or their combinations with epichlorohydrin, with sodium hydroxide as a catalyst. Zn‐Al LDH and Ce‐bentonite were produced through co‐precipitation and ion exchange techniques. Five eco‐friendly epoxy formulations were synthesized by varying the concentrations of resorcinol and isosorbide. The plain epoxy coating and composite coatings, consisting of 3, 5, or 7 wt.% LDH/clay fillers were analyzed. FTIR was used to examine the resin's epoxide groups. 100% RESO epoxy demonstrated superior adhesion, hardness, chemical resistance, water absorption, and corrosion prevention compared with other epoxy‐based coating formulations. When it comes to the mechanical properties of coatings, Zn‐Al LDH‐based coatings have better scratch hardness than Ce‐Bentonite due to their layered structure, which enables robust interfacial contact with epoxy and better stress transfer. Salt spray tests revealed that resorcinol‐based epoxy coatings with 5 wt.% filler exhibited outstanding corrosion resistance after 500 h. Therefore, this research offers bio‐based epoxies and LDH/clay composites as an environmentally friendly, high‐performance alternative to petroleum‐based BPA epoxies for anticorrosion coatings.

Dramatic mechanical increments of basalt fiber/phthalonitrile (BF/PN) composites by constructing a unique micro/nano hybrid interface

The weak interfacial interaction in basalt fiber reinforced polymer (BFRP) composite generally produces stress concentration failures. This study presents a method to enhance the interface properties in BF/PN composites by constructing a unique micro/nano hybrid interface onto BFs through the in situ complexation reaction and the subsequent introduction of CNTs. The muti-scale FePc/CNTs hybrid interface significantly improved the surface roughness/wettability of BFs and the mechanical properties of final BF/PN composites. A high flexural strength of 1098.8 MPa and a maximum ILSS of 62.8 MPa are observed in p-CNT3-BF/PN composites, increased by 64.8% and 93.2% compared with that of original BF/PN composite. The organic polar groups in FePc/CNTs hybrid improve interfacial compatibility and bonding of BFs with matrix, resulting in multi-scale interfacial interactions and stress transfer in BF/PN composites. This research will contribute to the construction of micro/nano hybrid interfaces onto fiber surface and offers valuable insights for the developments and applications of FRPs.

3D Printable One-Part Alkali-Activated Mortar Derived from Brick Masonry Wastes

The exponential growth in demand for housing has resulted in a greater focus on rapid construction methods that adhere to circular economy principles. 3D concrete printing is becoming a powerful tool to find solutions to the common challenges of affordable housing for more people, rapid construction, and the digitalization of the construction industry. However, a coherent synthesis of green and digital initiatives has not yet been achieved. For 3D printable materials, recycling of materials that have reached the end of their service life should also be enabled and supported, in line with circular economy goals that prioritize waste reduction and maximization of resource efficiency. With these objectives in mind, the current study focuses on the development of a one-part 3D printable alkali-activated mortar (3DPM) derived from brick masonry waste (BMW). BMWs were used as the main precursor and filler phase, whereas materials such as ground granulated blast furnace slag, kaolin clay, and limestone have been utilized to enhance/control the mechanical and rheological properties. To investigate the evolution of alkali-activation and the effect of anisotropy, the macromechanical properties of the developed 3DPM were investigated by compressive strength, flexural strength, split tensile, and direct tensile tests. The micromechanical properties were analyzed using X-ray fluorescence spectrometry (XRF), X-ray diffraction (XRD), Fourier transform infrared (FTIR), thermogravimetry (TG), differential scanning calorimetry (DSC), scanning electron microscopy and energy dispersive X-ray spectroscopy (SEM/EDX), and computed tomography (MicroCT) tests. Overall, the results revealed the presence of anisotropy, which can be reduced by optimizing the layer height. Through this optimization, reductions in pore content and distribution, validated by MicroCT, indicated that the disadvantage of the weak interlayer bond zone in stress transfer could be diminished. Micromechanical analysis showed that the gel formation responsible for the strength was the calcium-based gel structures. Considering these findings, it is believed that the BMW-based 3DPM can be an important alternative for the digitalization of the construction industry and its transition to a circular economy.