Linear Helical Printing (2025-04)¶

3D Concrete Printing (3DCP) offers remarkable capabilities for rapid and customizable construction, but its reliance on the layer-by-layer deposition method introduces a critical limitation: weak interfaces between layers that undermine structural performance. In this study, we propose a novel approach, linear helical printing, to address this issue. Unlike conventional techniques, our method creates a continuous filament of concrete in a helical path, resulting in a unified structure with enhanced integrity. To evaluate its effectiveness, we conducted experiments and finite element analysis, comparing the bending strength of hollow beams produced using our helical printing technique to those made with the traditional layer-by-layer method. The findings are compelling: linear helical printing consistently delivers superior bending strength and improved structural performance across all tested conditions. More specifically, the strength of a linear helical printed specimen with specific dimensions and inter-layer properties can be up to 97.3% higher than that of a layer-by-layer printed specimen. This approach not only simplifies the construction process but also has the potential to redefine 3DCP methodologies, offering a robust alternative for future construction applications.