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A review of numerical simulation methods in the manufacturing process of 3D printed concrete
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DOI：10.1007/s00170-026-18679-1.png)
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Abstract
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The absence of a systematic framework for process control and performance prediction remains a critical barrier to the widespread adoption of 3D concrete printing (3DCP). This review categorizes existing numerical approaches into three process-oriented stages: flow, printing, and hardened states. The Computational Fluid Dynamics (CFD) is critically evaluated for extrusion behavior, the Finite Element Method (FEM) is contrasted with mesh-free methods for structural stability and buildability under large deformation, and the Discrete Element Method (DEM) is assessed to quantify its role in analyzing fiber orientation and anisotropic mechanical properties. Findings reveal that although current models achieve high accuracy in individual stages, significant gaps persist in multi-physics coupling and multiscale integration. To address these limitations, synergistic pathways in thermo-hydro-mechanical-chemical (THMC) coupling and micro-macro modeling are identified, providing a strategic roadmap for enhancing the predictability and reliability of 3DCP manufacturing.
Keywords:
3D concrete printing
Numerical analysis
Buildability quantification
Printing process
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