Predicting the Tensile Performance of 3D-Printed PE Fibre-Reinforced ECC Based on Micromechanics Model

To elucidate the influence of the extrusion-based 3D printing of concrete on the tensile performance of polyethylene fibre-based engineered cementitious composites (PE-ECC), quantitative analyses of reinforcing filament alignment and pore morphology were carried out using backscattered electron (BSE) imaging and X-ray computed tomography (X-CT). A micromechanics analytical model based on microstructural characteristics was further employed to predict the tensile response of additively manufactured PE-ECC. Due to the extrusion process, fibres in 3D-printed PE-ECC were predominantly oriented along the printing path, resulting in a smaller average inclination angle compared with the randomly distributed fibres in cast specimens. Internal pores exhibited elongated flattened ellipsoidal shapes, with more pronounced anisotropy in axial lengths across the three principal directions. Taking the major semi-axis of the equivalent ellipsoidal voids as a representative pore parameter, the analytical model accurately reproduced the cracking strength, stress-strain evolution, and crack pattern of the printed PE-ECC. This extrusion process enhanced multiple cracking capacity and strain-hardening performance by improving fibre orientation, strengthening interfacial bonding, and altering matrix fracture toughness. The integration of micromechanical modelling with experimentally measured microstructural parameters effectively revealed the intrinsic mechanisms underlying the enhanced tensile behaviour of 3D-printed PE-ECC and provides theoretical support for the optimized design of fibre-reinforced cementitious composites in 3D printing.