Structural Optimization and Cost-Efficient Development of an Indigenous Gantry-Type 3D Concrete Printing System for Scalable Construction Applications (2026-03)¶

Three-dimensional concrete printing (3DCP) is gaining attention as an automated construction technology capable of reducing labour dependency, material waste, and construction time. However, most commercially available systems remain expensive and mechanically complex, limiting their wider adoption in developing construction environments. This study presents the design, structural evaluation, and experimental validation of an indigenous gantry-type 3D concrete printing system developed for cost-efficient construction applications. Three gantry frame configurations four-column, dual-column, and cantilever-type are designed and analyzed using STAAD.Pro to examine their structural response under operational loading conditions. The applied dead load of approximately 0.516 kN included the combined weight of stepper motors, nozzle assembly, and concrete retained within the extrusion system. Structural analysis indicated that the four-column configuration provided high stability but resulted in excessive structural weight (520.97 kg), while the cantilever configuration exhibited significant free-end deflection affecting positional accuracy. The dual-column gantry frame achieved the most balanced structural performance, reducing frame weight to 195.28 kg while maintaining acceptable stress distribution and operational stability. To improve motion smoothness and reduce vibration during printing, a rack and pinion mechanism was incorporated into the motion control system. The developed printer was fabricated and successfully validated through full-scale printing trials, including the construction of a security cabin wall. The results demonstrate that structurally optimized gantry systems can provide a practical and economically viable alternative to imported 3D concrete printing platforms.