2024 ASEE Annual Conference & Exposition

Additive manufacturing with concrete has surged over the last decade, potentially reshaping the landscape of the construction industry. This innovative technique introduces numerous engineering challenges due to the intersection of printer mechanics, volumetric extrusion dynamics, and performance-driven concrete mixture designs. In response to this evolving landscape, a integrative design project was modified to explore the emerging field of 3D printing with concrete. The objectives to this project include strengthening material design concepts, building experimental design skills, and providing hands-on experience with a new technology. Additionally, this project introduces the concept of prototyping a design which is not common in civil engineering. Students are tasked with designing and building an egg protection device using a 3D concrete printer. The initial phase consists of a mixture development phase followed by empirical testing of the fresh properties of their mixture to determine the optimal mortar mixture. In the second phase, students design their egg protection device, convert the model to machine code, print their structure and finally load test it. Reports are required at the end of each phase, and a summary presentation is made to the entire course at the end of the project. This project aims to improve several student outcomes such as experimental design and analysis, research of new technology, and communication. Initial student reflections were collected at the end of the project and are presented here. By intertwining contemporary technology with traditional course structures, we aim to reinforce the design thinking of students while providing hands-on experience with an emergent technology.