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<p>Direct Ink Writing (DIW) of cementitious materials presents a transformative approach for additive manufacturing in construction, enabling the fabrication of geometrically complex and material-efficient structures. However, the fidelity and structural performance of printed components are often compromised by gravitational asymmetries, especially during the deposition of overhangs, slanted contours, or unsupported geometries. The non-linear interactions among material rheology, extrusion dynamics, and gravity are not yet fully evaluated in open literature. To address this knowledge gap, this work develops a multiphase computational framework to simulate the coupled behavior of the extruded fluid and the surrounding air phases during DIW of cement-based inks. The incorporation of non-Newtonian rheology, transient behavior, and gravity-driven deformation allows the model to capture the temporal and spatial evolution of asymmetric layer shapes and structural instability. Validation is performed against experimental builds using high-resolution imaging and cross-sectional strand geometry analysis. The results reveal that gravitational asymmetries have an observable impact on strand morphology including strand height, width, and cross-sectional properties. In conclusion, this study offers a mechanistic understanding of printed strand morphology in DIW of cementitious materials and provides a simulation-guided pathway toward structurally robust, gravity-aware additive construction.</p>

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Multiphase computational modeling of gravitational asymmetry in direct ink writing of cementitious materials

  • 期刊论文

  • 发表日期：

    2026年3月14日

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  • Marissa Loraine Scalise,
  • Satadru Dey,
  • Amrita Basak

摘要

Direct Ink Writing (DIW) of cementitious materials presents a transformative approach for additive manufacturing in construction, enabling the fabrication of geometrically complex and material-efficient structures. However, the fidelity and structural performance of printed components are often compromised by gravitational asymmetries, especially during the deposition of overhangs, slanted contours, or unsupported geometries. The non-linear interactions among material rheology, extrusion dynamics, and gravity are not yet fully evaluated in open literature. To address this knowledge gap, this work develops a multiphase computational framework to simulate the coupled behavior of the extruded fluid and the surrounding air phases during DIW of cement-based inks. The incorporation of non-Newtonian rheology, transient behavior, and gravity-driven deformation allows the model to capture the temporal and spatial evolution of asymmetric layer shapes and structural instability. Validation is performed against experimental builds using high-resolution imaging and cross-sectional strand geometry analysis. The results reveal that gravitational asymmetries have an observable impact on strand morphology including strand height, width, and cross-sectional properties. In conclusion, this study offers a mechanistic understanding of printed strand morphology in DIW of cementitious materials and provides a simulation-guided pathway toward structurally robust, gravity-aware additive construction.