Experimental 3D Printing of Overhangs by Integrated Mixing-Extrusion Process

Experimental 3D Printing of Overhangs by Integrated Mixing-Extrusion Process | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Experimental 3D Printing of Overhangs by Integrated Mixing-Extrusion Process Alexandr Gubanov, Viktor Kutugin, Olesia Antiushenia This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6487469/v2 This work is licensed under a CC BY 4.0 License Status: Posted Version 2 posted You are reading this latest preprint version Show more versions Abstract Achieving complex geometries in extrusion-based concrete 3D printing has become a subject of growing interest, particularly in applications requiring overhangs, such as domes and arches. While most existing extrusion-based technologies are limited to printing primarily vertical walls, emerging methods are being developed to enable the printing of structures with overhangs. This paper introduces an innovative approach to 3D construction printing (3DCP) that accommodates overhangs. The approach integrates changes to both the printing process and the material formulation. A key modification to the printing process is mixing dry and liquid components immediately before extrusion, which eliminates the requirement for prolonged pumpability in the fresh-state mixture. A clay-based concrete was developed for 3D printing, where the clay content was optimized to deliver the specific fresh-state properties for the novel extrusion process, while also meeting the required hardened-state strength. The test prints demonstrated the effectiveness of the method, successfully achieving overhangs greater than 45 degrees on a simple Cartesian 3D printer. The fresh-state mixture exhibits Bingham behavior, with a yield stress between 0.2 and 0.3 MPa. The hardened mixture achieves compressive strengths between 10 and 40 MPa and flexural strengths between 3.5 and 4.5 MPa, making it suitable for creating durable formworks. 3DCP extrusion-based 3D printing clay-based concrete overhang printing printhead rheological properties Full Text Additional Declarations The authors declare no competing interests. Cite Share Download PDF Status: Posted Version 2 posted You are reading this latest preprint version Show more versions Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6487469","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":455945205,"identity":"bcfd165c-2f90-4a6f-bda8-bcefb6ee2837","order_by":0,"name":"Alexandr Gubanov","email":"","orcid":"https://orcid.org/0000-0001-7465-6238","institution":"Moscow Institute of Physics and Technology","correspondingAuthor":false,"prefix":"","firstName":"Alexandr","middleName":"","lastName":"Gubanov","suffix":""},{"id":455945206,"identity":"35ee40c7-5e2a-4ca3-8353-3f17ed64d2f9","order_by":1,"name":"Viktor Kutugin","email":"","orcid":"https://orcid.org/0000-0002-6847-6385","institution":"Tomsk Scientific Center of the Siberian Branch of the Russian Academy of Sciences","correspondingAuthor":false,"prefix":"","firstName":"Viktor","middleName":"","lastName":"Kutugin","suffix":""},{"id":455945207,"identity":"c39c7146-b6c9-4a1e-8673-fa848085abca","order_by":2,"name":"Olesia Antiushenia","email":"data:image/png;base64,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","orcid":"https://orcid.org/0009-0001-1879-6110","institution":"Tomsk Polytechnic University","correspondingAuthor":true,"prefix":"","firstName":"Olesia","middleName":"","lastName":"Antiushenia","suffix":""}],"badges":[],"createdAt":"2025-04-20 05:08:08","currentVersionCode":2,"declarations":{"humanSubjects":false,"vertebrateSubjects":false,"conflictsOfInterestStatement":false,"humanSubjectEthicalGuidelines":false,"humanSubjectConsent":false,"humanSubjectClinicalTrial":false,"humanSubjectCaseReport":false,"vertebrateSubjectEthicalGuidelines":false},"doi":"10.21203/rs.3.rs-6487469/v2","doiUrl":"https://doi.org/10.21203/rs.3.rs-6487469/v2","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":103507513,"identity":"95e8f806-3932-43fa-ac7d-45f2af5eee44","added_by":"auto","created_at":"2026-02-26 13:41:39","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":2915743,"visible":true,"origin":"","legend":"","description":"","filename":"PreprintUpdatedExperimental3DPrintingofOverhangsbyIntegratedMixingExtrusionandClayBasedConcreteFormulations.pdf","url":"https://assets-eu.researchsquare.com/files/rs-6487469/v2_covered_9c8f1bad-2ef9-4502-9dd6-0c763ddfd0d8.pdf"}],"financialInterests":"The authors declare no competing interests.","formattedTitle":"\u003cp\u003eExperimental 3D Printing of Overhangs by Integrated Mixing-Extrusion Process\u003c/p\u003e","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"3DCP, extrusion-based 3D printing, clay-based concrete, overhang printing, printhead, rheological properties","lastPublishedDoi":"10.21203/rs.3.rs-6487469/v2","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-6487469/v2","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eAchieving complex geometries in extrusion-based concrete 3D printing has become a subject of growing interest, particularly in applications requiring overhangs, such as domes and arches. While most existing extrusion-based technologies are limited to printing primarily vertical walls, emerging methods are being developed to enable the printing of structures with overhangs. This paper introduces an innovative approach to 3D construction printing (3DCP) that accommodates overhangs. The approach integrates changes to both the printing process and the material formulation. A key modification to the printing process is mixing dry and liquid components immediately before extrusion, which eliminates the requirement for prolonged pumpability in the fresh-state mixture. A clay-based concrete was developed for 3D printing, where the clay content was optimized to deliver the specific fresh-state properties for the novel extrusion process, while also meeting the required hardened-state strength. The test prints demonstrated the effectiveness of the method, successfully achieving overhangs greater than 45 degrees on a simple Cartesian 3D printer. 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