Wood-Waste-Based Artificial Aggregates for Extrusion 3D-Printed Cementitious Composites: Hydration, Printability, and Mechanical Performance

This study investigates the feasibility of incorporating wood-based waste in cementitious composites for extrusion-based three-dimensional (3D) printing through the production of artificial aggregates. Because lignocellulosic residues can retard cement hydration, wood dust was chemically modified with a calcium nitrate-based accelerator and granulated into aggregates using disc granulation. The resulting aggregates were characterized for mechanical robustness, and their influence on cement hydration and microstructural development was evaluated using X-ray diffraction (XRD) and thermogravimetric/differential scanning calorimetry (TG/DSC). The modified aggregates were then incorporated into 3D printable cementitious mixtures to assess fresh-state properties, printability, and mechanical performance. The accelerator affected hydration by increasing bound water content and altering the development of hydration products. The produced aggregates exhibited sufficient crushing resistance for practical handling. The incorporation of artificial aggregates resulted in reduced compressive and flexural strengths compared to the reference mixture. However, the differences between mechanical properties measured in different loading directions were reduced, indicating a more uniform structural response in printed elements. The findings demonstrate that chemically treated wood-based aggregates can be successfully integrated into 3D printable cementitious systems, offering a promising pathway toward more sustainable construction materials.