Comparative evaluation of the physical and mechanical properties of artificial rocks fabricated using four 3D printing technologies

Purpose This study aims to compare and evaluate the physical and mechanical properties of artificial rocks fabricated using four 3D printing (3DP) technologies, with the goal of identifying their suitability for rock mechanics applications. Design/methodology/approach Artificial rock specimens were fabricated using fused deposition modeling (FDM), stereolithography (SLA), powder-based 3DP and wet-material extrusion deposition modeling (WEDM). A comprehensive evaluation was conducted by analyzing the dimensional accuracy, surface microstructural features, ultrasonic wave velocity and mechanical behavior under uniaxial compression. Findings SLA-fabricated resin specimens achieved the highest dimensional accuracy and exhibited a nearly isotropic peak strength of 77.68 MPa. FDM-fabricated PLA specimens showed comparable dimensional accuracy but displayed pronounced plastic deformation and lower peak strength in the Z direction. Powder-based 3DP gypsum specimens exhibited the most pronounced anisotropy, with the Z-direction peak strength nearly 50% lower than the Y direction. WEDM-fabricated gypsum specimens showed relatively consistent peak strengths ranging from 7.85 to 8.73 MPa and brittle failure characterized by axial splitting, closely resembling that of natural rocks. Originality/value To the best of the authors’ knowledge, this study presents the first systematic comparison of artificial rock specimens fabricated using four 3D printing technologies. The findings provide a scientific basis for selecting and optimizing 3DP technologies in experimental rock mechanics.