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Systematic Workflow for Digital Design and On-Site 3D Printing of Large Concrete Structures (2025-03)

A Case Study of a Full-Size Two-Story Building

10.1016/j.jobe.2025.112370

 Zuo Zibo,  Zhang Yamei, Li Jin, Huang Yulin, Zhang Longlong, Wang Xianggang,  Tao Yaxin,  de Corte Wouter
Journal Article - Journal of Building Engineering, No. 112370

Abstract

Numerous trial projects for 3D printed large concrete structures have been built around the world. However, the systematic coverage of the entire design and printing process is very limited. This paper presents a systematic workflow for the digital design and on-site 3D printing of large concrete structures, using a full-size 3D printed two-story building as a case study. To ensure the safety of 3D printed concrete structures, the proposed workflow fully considers the differences between printed and cast-in-place structures, and the design and construction are guided by the most unfavorable factors by introducing some discount factors. Specifically, the workflow covers 6 stages, i.e., computational conversion and design of structures, establishment of optimal construction methods, presetting of printing parameters, virtual printing and test evaluation, preparation and commissioning prior to printing, and on-site printing and monitoring. Using the workflow, the building with a height of 6 meters was successfully designed and printed with a small print deviation, and the maximum deviation of the height was controlled to 10 mm. The proposed workflow has the potential to become a common standard for 3D printing of large concrete buildings or structures, and can facilitate the widespread application of 3D printing.

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BibTeX 
@article{zuo_zhan_li_huan.2025.SWfDDaOS3PoLCS,
  author            = "Zibo Zuo and Yamei Zhang and Jin Li and Yulin Huang and Longlong Zhang and Xianggang Wang and Yaxin Tao and Wouter de Corte",
  title             = "Systematic Workflow for Digital Design and On-Site 3D Printing of Large Concrete Structures: A Case Study of a Full-Size Two-Story Building",
  doi               = "10.1016/j.jobe.2025.112370",
  year              = "2025",
  journal           = "Journal of Building Engineering",
  pages             = "112370",
}
Formatted Citation

Z. Zuo, “Systematic Workflow for Digital Design and On-Site 3D Printing of Large Concrete Structures: A Case Study of a Full-Size Two-Story Building”, Journal of Building Engineering, p. 112370, 2025, doi: 10.1016/j.jobe.2025.112370.

Zuo, Zibo, Yamei Zhang, Jin Li, Yulin Huang, Longlong Zhang, Xianggang Wang, Yaxin Tao, and Wouter de Corte. “Systematic Workflow for Digital Design and On-Site 3D Printing of Large Concrete Structures: A Case Study of a Full-Size Two-Story Building”. Journal of Building Engineering, 2025, 112370. https://doi.org/10.1016/j.jobe.2025.112370.