Three-Dimensional Printing Using Recycled High-Density Polyethylene: Technological Challenges and Future Directions for Construction

Abstract

Three-dimensional (3D) printing technologies are transforming the design and manufacture of components and products across many disciplines, but their application in the construction industry is still limited. Material deposition processes can achieve infinite geometries. They have advanced from rapid prototyping and model-scale markets to applications in the fabrication of functional products, large objects, and the construction of full-scale buildings. Many international projects have been realised in recent years, and the construction industry is beginning to make use of such dynamic technologies. Advantages of integrating 3D printing with house construction are significant. They include the capacity for mass customisation of designs and parameters to meet functional and aesthetic purposes, the reduction in construction waste from highly precise placement of materials, and the use of recycled waste products in layer deposition materials. With the ultimate goal of improving construction efficiency and decreasing building costs, the researchers applied Strand 7 Finite Element Analysis software to a numerical model designed for 3D printing a cement mix that incorporates the recycled waste product high-density polyethylene (HDPE). The result: construction of an arched, truss-like roof was found to be structurally feasible in the absence of steel reinforcements, and lab-sized prototypes were manufactured according to the numerical model with 3D printing technology. 3D printing technologies can now be customised to building construction. This paper discusses the applications, advantages, limitations, and future directions of this innovative and viable solution to affordable housing construction.