Additive Manufacturing of Cementitious Materials by Selective Paste Intrusion: Numerical Modeling of the Flow Using a 2D Axisymmetric Phase Field Method

The 3D printing of concrete has now entered a new era and a transformation of the construction sector is expected to reshape fabrication with concrete. This work focuses on the selective paste intrusion method, which consists of bonding dry particles of aggregate with a cement paste. This innovative technique could lead to the production of very precise component for specific applications. The main obstacle to tackle in order to reach a high shape accuracy of high mechanical performances of 3D printing elements by selectively activating the material is the control of the distribution of the cement paste through the particle bed. With the aim to better understand the path followed by the solution as it penetrates a cut-section of the granular packing, two-dimensional numerical modeling is carried out using Comsol software. A phase-field method combined with a continuous visco-plastic model has been used to study the influence of the average grain diameter, the contact angle, and the rheological properties of cement pastes on the penetration depth. We compare the numerical modeling results to existing experimental results from 3D experiments and a one-dimensional analytical model. We then highlight that the proposed numerical approach is reliable to predict the final penetration of the cement pastes.