Numerical Investigation of Fresh Concrete Extrusion in 3D Concrete Printing Using an Enhanced DEM–DFC Framework
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Three-dimensional concrete printing (3DCP) is increasingly recognized as an innovative fabrication approach in civil engineering, providing notable benefits in terms of automation and geometric freedom. Nevertheless, achieving reliable material deposition remains challenging, as the rheological response of printable concrete strongly influences filament geometry and structural integrity during printing. In this work, a Discrete Element Method (DEM) framework [1] incorporating the Discrete Fresh Concrete (DFC) model [2] is developed to numerically investigate the extrusion behavior of fresh concrete. The proposed formulation is applied to evaluate the influence of printing speed and mixture composition on the performance of single-layer deposition. During this analysis, shortcomings of the original DFC model are observed in its ability to capture tangential interactions and dissipative effects at particle–particle and particle–substrate contacts. To address these issues, extensions of the material model are proposed by introducing static friction and rolling resistance, as suggested by the authors in [3]. The numerical results demonstrate that the improved DFC-based DEM framework can effectively reproduce key features of the printing process, such as filament formation and layer continuity, and represents a promising tool for the analysis and optimization of 3DCP processes. [1] E. M. B. Campello. A computational model for the simulation of dry granular materials. International Journal of Non-Linear Mechanics, vol. 106, pp. 89–107, 2018. [2] G. Cusatis and E. Ramyar. Discrete Fresh Concrete Model for Simulation of Ordinary, Self-Consolidating, and Printable Concrete Flow. Journal of Engineering Mechanics, vol. 148, 2021. [3] V. H. M. Avancini, O. D. Quintana-Ruiz and E. M. B. Campello. Modeling 3D concrete printing through the combined DEM-discrete fresh concrete approach. Computational Particle Mechanics (accepted for publication), 2026.
