3D Concrete Printing: Optimizing the Design of Interlocking 3D Printed Concrete Blocks for Fast and Sustainable Construction

¹ Laboratoire Technologies et Services Industriels, EST, Sidi Mohamed Ben Abdellah University, Fez, Morocco
² Civil Engineering Department, ENSAM, Moulay Ismail University, Meknes, Morocco

^* Corresponding author: mouad.elmesoudy@usmba.ac.ma

Abstract

In a world where construction faces environmental challenges and high labor de-mands, optimizing sustainable methods is crucial. 3D Concrete Printing (3DCP) stands out as an innovative, efficient technique, eliminating molds, reducing waste, and enhancing design flexibility while significantly improving construc-tion speed and cost effectiveness. This study explores interlocking 3D printed concrete blocks as an alternative to traditional modular construction, minimizing mortar dependency for rapid, precise assembly and increasing structural stability. Experimental validation examines geometric accuracy, mechanical strength, and printing efficiency, proving that 3DCP blocks can match or surpass conventional ones. Customizable thermal, acoustic, and mechanical properties, enhanced by specialized concrete mixtures and reinforcements, expand its construction applica- tions. By bridging automation and sustainability, this work demonstrates 3D printed modular construction’s potential for cost-effective, scalable, and eco-friendly building solutions, particularly for rapid housing, disaster relief, infra-structure development, and customized architectural projects.