Industrial-Scale Quality Control of 3D Printed Concrete via Multi-Parameter Inline Process Monitoring for Next Generation Systems

• Applicant: Dr. Freek Bos
• Subject Area: Structural Engineering, Building Informatics and Construction Operation ; Construction Material Sciences, Chemistry, Building Physics
• Term: since 2026
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 573348712

3D Concrete Printing (3DCP) has emerged as a promising novel construction method with the potential to significantly reduce material use and construction waste and decrease health hazards, as well as increase productivity, automation and geometrical freedom. However, due to complexities inherent in the process, 3DCP suffers from quality variations that constitute an important obstacle for main stream adoption of the technology. It is hypothesized that, besides material composition and fixed parameters related to equipment, these quality variations are related to measurable process parameters, such as temperatures, pressures, mass deposition rate, filament geometry, etc. Recent studies support this but have been too limited in scope to comprehensively link process parameters to quality control of 3D printed concrete. Furthermore, they are generally performed on small scale, academic 3DCP facilities rather than large industrial ones. The goal of this proposed project is to develop, implement and evaluate an inline, multi-parameter process monitoring system for 3DCP for quality control within an industrial environment. This system aims to provide robust quality control by correlating real-time measured process parameters with process stability, rheological and fresh-state properties, geometrical accuracy, and mechanical performance. Building upon an innovative experimental monitoring framework previously developed at TU Munich (TUM), the system will facilitate real-time adjustments of process parameters. It will be integrated into the facilities of a leading German industrial partner specialized in 3DCP, which is currently upgrading to a next-generation system capable of utilizing generic, locally-sourced concrete mixtures. The goal will be achieved by (i) installing an extensive process monitoring system at the industrial partner, (ii) developing a data mapping method to link measured features to specific locations in a printed object, and (iii) determine quantitative criteria for 5 quality Key Performance Indicators (KPI). Subsequently, data will be collected from various printing sessions at the academic facilities (TUM) and the industrial facilities, and offline experiments (iv). These will be analyzed for correlations using explicit statistical methods as well as AI (v). Based on the outcomes, acceptance criteria (acceptable threshold values) for the process parameters will be set (vi) and a user interface will be developed (vii) to allow easily accessible interpretation of monitored data during printing by operation staff.

• DFG Programme: Research Grants (Transfer Project)
• Application Partner: INSTATIQ GmbH