Optimizing printing and rheological parameters for 3D printing with cementitious materials

In 3D printing, selecting appropriate printing parameters based on material rheology is critical for achieving compatible filaments with optimal performance. However, the process of aligning printing parameters with rheological properties lacks a robust theoretical foundation. This study investigates the influence of printing and rheological parameters on the relative printing length of molded filaments, categorizing them into three distinct printing conditions. Computational Fluid Dynamics (CFD) simulations model the slurry extrusion process, analyzing the cross-sectional shape, stress distributions, extruded profile changes, surface roughness, and pore structure under varying conditions. The optimal printing condition is identified based on filament characteristics, aiming to establish a theoretical basis for synchronizing rheological and printing parameters in practical applications. •The impact of printing parameters and material rheology on the quality of cementitious filaments in 3D printing was investigated.•CFD simulations were deployed to analyze extrusion behavior and stress distribution, with findings validated through experimentation.•Optimal printing conditions for achieving smooth surface quality and reduced porosity in printed structures were identified.•A theoretical framework was provided to align rheological properties with printing parameters, contributing to enhanced precision control in 3D concrete printing applications.