INFLUENCE OF 3D PRINTER DESIGN CHARACTERISTICS ON EXTRUSION QUALITY

Abstract

Concrete and mortar mixtures used in construction-scale 3D printing must meet a set of specific requirements dictated by the nature of additive manufacturing processes. A key prerequisite for achieving high-quality printed structures is the complementary interaction between the rheological properties of the construction mixture and the technological characteristics of the 3D printer. The overall quality of 3D printing is a multifactorial indicator formed under the influence of mechanical, technological, and control-related parameters of the printing system. Among these, extrusion-related parameters—particularly nozzle travel speed and material feed rate—play a decisive role. This study investigates the influence of nozzle movement speed and construction mixture feed rate on the quality of extrusion during construction 3D printing. The experimental program was carried out using a laboratory-scale 3D printer and designed according to a two-factor, three-level experimental plan. The extrusion quality index was adopted as an integral response parameter, enabling a comprehensive assessment of flow stability, layer uniformity, and geometric consistency of the printed filament.

Experimental results were processed using statistical methods of design of experiments, resulting in the development of an adequate second-order regression model. The model reveals a nonlinear relationship between the technological parameters and extrusion quality, as well as a significant interaction effect between nozzle speed and material feed rate. An excessive increase in nozzle travel speed without a corresponding adjustment of the feed rate leads to extrusion discontinuities and reduced interlayer adhesion, while overly high material feed rates cause flow instability and geometric deformation of the printed layer. The proposed mathematical model enables quantitative prediction of extrusion quality within the investigated parameter range and can be effectively used for optimizing 3D printing process parameters. The obtained results contribute to improving the stability of the additive manufacturing process and enhancing the structural quality of construction elements produced by 3D printing technologies.

1. Perrot A., Rangeard D., Pierre A.Structural built-up of cement-based materials used for 3D-printing extrusion techniques. Materials and Structures, 2016. https://doi.org/10.1617/s11527-016-0848-4.
2. Марчук В.В., Дворкін Л.Й., Макаренко Р.М. Вплив параметрів та критерій визначення якості екструзії при 3D-друці. Вісник НУВГП. Технічні науки. Том 3 № 113 (2026).
3. Hager, I.; Golonka, A.; Putanowicz, A. 3D printing of buildings and building components as the future of sustainable construction? Proc. Eng. 2016, Vol. 151, pp. 292–299. https://doi.org/10.1016/j.proeng.2016.07.357
4. Nan Zhang, Jay Sanjayan, «Extrusion nozzle design and print parameter selections for 3D concrete printing», «Cement and Concrete Composites» (2023). https://doi.org/10.1016/j.cemconcomp.2023.104939
5. «Sanjayan J., Nematollahi B., Xia M., Marchment T. Effect of printing parameters on interlayer bond strength of 3D printed concrete. Construction and Building Materials, 2018. https://doi.org/10.1016/j.conbuildmat.2018.03.232
6. «Dong An, Mahfuzur Rahman, Y.X. Zhang, Richard (Chunhui) Yang, Effects of Key 3D concrete printing process parameters on layer shape: Experimental study and Smooth Particle Hydrodynamics modelling, Case Studies in Construction Materials, Volume 22,2025, https://doi.org/10.1016/j.cscm.2025.e04718.
7. Havryliak S.A. New technologies in the field of construction. Using 3D printers», // Theory and building practice. видавництво Львівської політехніки.- 2021. - Вип. 3, №. 1. - С. 15-22. https://doi.org/10.23939/jtbp2021.01.015
8. Buswell R.A., Leal de Silva W., Jones S.Z., Dirrenberger J. 3D printing using concrete extrusion: A roadmap for research. Cement and Concrete Research, 2018. https://doi.org/10.1016/j.cemconres.2018.05.006.
9. Savytskyi M.V., Shatov S.V., Ozhyshchenko O.A., «3D-друк будівельних об’єктів», «Вісник Придніпровської державної академії будівництва та архітектури». 2020. Вип. 2, С. 59–68.
10. Dvorkin, L.; Dvorkin, O.; Ribakov, Y. Mathematical experiments planning in concrete technology. Nova Science Publishers: New York, USA, 2011, 173 p.