Material-Saving Concrete Ceiling Made from 3D-Printed Interlocking Blocks (2024-10)¶

A new modular construction principle has the potential to revolutionize concrete construction: topological interlocking of building blocks. The innovative arrangement of these interlocking blocks effectively prevents kinematic loading of individual building blocks by the entire assembly by immobilizing each other. This study investigates the synergy between topological interlocking assemblies (TIA) and 3D concrete printing and conducts a comprehensive analysis of the manufacturing processes and structural performance. The interlocking blocks, which interlock without binders, offer outstanding prospects for sustainable construction. The study presents a method to optimize block geometries for 3D printing to ensure interlocking integrity. Three specific block geometries are developed and tested for 3D concrete printing. Different methods are used to produce interlocking blocks. A geometry is selected and tested at both small and large scale. Experimental testing, including precise 3D photogrammetry measurements, will follow to evaluate the structural behavior of these plate systems. The results impressively demonstrate the feasibility and enormous potential of integrating topological interlocking and 3D concrete printing for sustainable construction applications.