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This research aims to design and develop a proof-of-concept system for three-dimensional (3D) printing of fly ash-based geopolymer materials. The primary focus of this research was designing and creating a 3D printer capable of printing straight multi-layered geopolymer walls. The geopolymer mixture consists of fly ash, an industrial waste by-product, sand, sodium silicate, sodium hydroxide, and water. Through the controlled application of AC voltage, the natural resistance of the geopolymer causes heat generation through a phenomenon known as ohmic heating. This heating method rapidly cures the geopolymer in as little as five (5) minutes based on volume. Several off-the-shelf 3D printer designs were studied to understand the working principle, and ultimately, the final design was developed based on the necessary design criteria. This design allowed the printer to extrude geopolymer through a rotating auger assembly. Parallel copper electrodes mounted at the end of the extruder allow AC voltage to apply through the uncured geopolymer and heat it as it is extruded. Following many trials, the developed printer provided proof of concept for a viable electrically heated rapid-setting geopolymer 3D-printed wall. This design effectively demonstrates that with further development, the 3D printing of geopolymer can potentially serve as an eco-friendly alternative to 3D-printed concrete.

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Three-Dimensional Printing of Fly Ash-Based Geopolymer Materials

  • 会议论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年

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  • Shaurav Alam,
  • Stephen Gordon,
  • Blake Bassett,
  • Kevin Cobb,
  • Brandon Jefferson,
  • Nnamdi Nwoha,
  • Tanvir Manzur,
  • Kelly Crittenden,
  • John Matthews

摘要

This research aims to design and develop a proof-of-concept system for three-dimensional (3D) printing of fly ash-based geopolymer materials. The primary focus of this research was designing and creating a 3D printer capable of printing straight multi-layered geopolymer walls. The geopolymer mixture consists of fly ash, an industrial waste by-product, sand, sodium silicate, sodium hydroxide, and water. Through the controlled application of AC voltage, the natural resistance of the geopolymer causes heat generation through a phenomenon known as ohmic heating. This heating method rapidly cures the geopolymer in as little as five (5) minutes based on volume. Several off-the-shelf 3D printer designs were studied to understand the working principle, and ultimately, the final design was developed based on the necessary design criteria. This design allowed the printer to extrude geopolymer through a rotating auger assembly. Parallel copper electrodes mounted at the end of the extruder allow AC voltage to apply through the uncured geopolymer and heat it as it is extruded. Following many trials, the developed printer provided proof of concept for a viable electrically heated rapid-setting geopolymer 3D-printed wall. This design effectively demonstrates that with further development, the 3D printing of geopolymer can potentially serve as an eco-friendly alternative to 3D-printed concrete.