Recycled Waste Materials Utilised in 3D Concrete Printing for Construction Applications (2025-10)¶

Three-dimensional concrete printing (3DCP), an innovative fabrication technique, has emerged as an environmentally friendly digital manufacturing process for using recycled waste materials in the construction industry. The aim of this review paper is to critically evaluate the current state of research on the use of recycled materials such as aggregates and powders in 3DCP, correlating the environmental, economic, and performance parameter effects. This review comprehensively evaluates the potential benefits of incorporating recycled waste materials in 3D printing by critically reviewing the existing peer-reviewed articles through a scientometric review. The resulting bibliometric analysis identified 73 relevant papers published between 2018 and 2024. Through the critical review, five main research categories were identified: recycled materials in 3DCP arising mainly from construction demolition in powder and aggregate forms, which investigates the types of recycled materials used, their extraction methods, morphology and physical and chemical properties. The morphology properties of the materials used displayed high irregularities in terms of shape and percentage of adhered mortar. In the second category, printability and performance, the buildability, rheological properties and the mechanical performance of 3DCP with recycled materials were investigated. Category 3 assessed the latest developments in terms of 3D-printed techniques, including Neural Networks, in predicting performance. Category 4 analysed the environmental and economic impact of 3DCP. The results indicated anisotropic behaviour for the printed samples influencing mechanical performance, with the parallel printing direction showing improved performance. The environmental performance findings indicated higher global warming potential when comparing 3DCP to cast-in situ methods. This impact was reduced by 2.47% when recycled aggregates and binder replacements other than cement were used (fly ash, ground slag, etc.). The photochemical pollution impact of 3DPC was found to be less than that of cast-in situ, 0.16 to 0.18 C2H4-eq. This environmental impact category was further reduced up to 0.10 C2H4-eq following 100% replacement. Lastly, category 5 explored some of the challenges and barriers for the implementation of 3DCP with recycled materials. The findings highlighted the main issues, namely inconsistency in material properties, which can lead to a lack of regulation in the industry.