Researchers from University of New Mexico have created a milestone in civil construction: a bendable concrete designed for printing 3D.
Innovation, the result of Department of Civil, Construction and Environmental Engineering Gerald May, promises to revolutionize structures such as buildings and bridges, making them more resilient and less dependent on maintenance.
The patented material is an advanced alternative to conventional methods, which often require steel reinforcements and high operating costs. It opens doors to a future where construction is safer, more efficient and automated.
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Rethinking traditional construction
Traditional construction relies on heavy machinery and extensive human effort to shape and position materials such as steel or wood.
Although concrete is extremely strong in compression, it is known for its brittleness under tension, which results in frequent cracking.
"If you try to pull apart a piece of concrete, it breaks easily. This is because the material has no tensile properties.“, explained Maryam Hojati, assistant professor at UNM and leader of the research.
Earthquakes, strong winds and other natural forces worsen the problem, exposing the vulnerability of structures made of conventional concrete. Hojati adds: “Concrete works well for compression, but is a poor material for handling tension.".
While many advances are being made globally, existing 3D printing techniques still rely on traditional reinforcements such as rebar, limiting the full potential for automation.
The Science of Bendable Concrete
Ph.D. graduate Muhammad Saeed Zafar, one of the researchers on the project, has developed a revolutionary blend composed of polymer fibers that increase flexibility and tensile strength.”Compared to metals or plastics, 3D printing in concrete is still in its early stages of development. Our goal was to overcome the limitations of reinforcement“, Zafar said.
The composition includes materials such as polyvinyl alcohol, silica fume, fly ash and ultra-high molecular weight polyethylene fibers. These components ensure that the concrete is both strong and flexible.
"This material holds concrete together even when subjected to tension or bending loads.“, explained Hojati.
The new mixture showed deformation up to 11,9% greater than conventional concrete, making it ideal for 3D printing as it maintains viscosity and prevents clogging in printer nozzles.
The development required rigorous testing. Small structures, such as prisms and dog-bone-shaped objects, were printed and evaluated for strength.
The main goal was to create a material that was not only printable, but also structurally viable for large-scale use.
A future beyond Earth
The applications of this concrete go beyond the Earth’s environment. NASA, for example, is evaluating 3D printing technologies to build habitats on other planets.
Transporting large quantities of materials into space is impractical, making UNM's innovation a potential solution for space exploration.
On the ground, bendable concrete has the potential to transform the construction industry. In addition to greater resilience to natural disasters, it reduces costs and risks by promoting greater automation.
"This research is a milestone. It combines structural feasibility with 3D printing technology to deliver a highly innovative solution.“, concluded Hojati.