Abstract
A material model for a sustainable additive manufacturing (AM) concrete mix based on cement replacement with calcined clay was calibrated using Drucker-Prager plasticity in the simulation of uniform unconfined compressive strength tests of concrete at early ages of 15, 30, 45, 60, and 90 min. A time-dependent AM concrete mix material model was then used to simulate the stability of depositing layers of different thickness, width, and overhang with different printing speeds. Simulation was verified experimentally with trial prints of cylindrical shape. Success was assessed by the number of stable layers under given conditions. This method was automated using parametric modelling software and FEA solver ABAQUS to generate over 270 simulations with varying geometry and deposition time. A framework connecting early age compressive tests to stability prediction and decision-support in the design and manufacturing of AM components with custom concrete was proposed and tested. Data from a computed set of simulations were used to build a probabilistic surrogate model targeting interactive exploration of the results by operators and designers