Impact of Robotic 3D Printing Process Parameters on Bond Strength

Additive manufacturing (AM), also known as 3D printing, offers advantages over traditional construction technologies, increasing material efficiency, fabrication precision, and speed. However, many AM projects in academia and industrial institutions do not comply with building codes. Consequently, they are not considered safe structures for public utilization and have languished as exhibition prototypes. While three discrete scales—micro, mezzo, and macro—are investigated for AM with paste in this paper, structural integrity has been tackled on the mezzo scale to investigate the impact of process parameters on the bond strength between layers in an AM process. Real-world material deposition in a robotic-assisted AM process is subject to environmental factors such as temperature, humidity, the load of upper layers, the pressure of the nozzle on printed layers, etc. Those factors add a secondary geometric characteristic to the printed objects that was missing in the initial digital model. This paper introduces a heuristic workflow for investigating the impacts of three selective process parameters on the bond strength between layers of paste in the robotic-assisted AM of large-scale structures. The workflow includes a method for adding the secondary geometrical characteristic to the initial 3D model by employing X-ray computerized tomography (CT) scanning, digital image processing, and 3D reconstruction. Ultimately, the proposed workflow offers a pattern library that can be used by an architect or artificial intelligence (AI) algorithms in automated AM processes to create robust architectural forms.