3DCP composite systems: Additive manufacturing of a concrete and cellulose interlocking wall

Abstract This study explores the sequential use of Additive Manufacturing with two distinct materials– concrete and cellulose– for the fabrication of a modular hybrid wall system made up of a set of uniquely shaped, self-supporting interlocking blocks. At a functional level, the proposed system is composed of two layers: (1) a 3D-printed structural concrete panel which forms the exterior finish and ensures the fit between components; and (2) a 3D-printed cellulose coating that forms the interior finish of the wall and plays the role of acoustic insulator through a formal optimization process. Furthermore, the block design supports dry assembly and disassembly, aligning with principles of Design for Disassembly and promoting reusability. A full-scale wall section is prototyped and compared to its digital model to evaluate geometric conformity and assembly performance. This research underscores both the potential and current limitations of combining 3D Concrete Printing with 3D-printed biomaterials, advancing towards prefabrication solutions for adaptable, circular construction practices.