Advanced 3D-Printed Ceramic–Concrete Composite Materials for Next-Generation Sustainable Construction

Abstract

ABSTRACT Additive manufacturing (3D printing) in civil engineering is transitioning from niche prototype demonstrations to scalable structural deployment. However, conventional 3D-printed concrete (3DPC) matrices suffer from poor tensile strength, inter-layer weak zones, high embodied carbon, and limited thermal performance. This comprehensive review examines the integration of advanced ceramic precursors and industrial ceramic waste micro-particles into concrete systems to create high-performance 3D-printed ceramic concrete composites (CCCs). By incorporating waste porcelain, sanitaryware micro-powder, expanded clay, and geopolymerized ceramic aggregates into 3D printable mixtures, CCCs achieve a 32% increase in 28-day compressive strength, a 45% enhancement in interlayer bond shear strength, and a 28% reduction in life-cycle embodied carbon compared to traditional Portland cement formulations. The review systematically evaluates ink rheology (thixotropy, static yield stress evolution, buildability), extrusion mechanics, microstructural interfacial transition zone (ITZ) densification, and thermomechanical resilience under elevated temperatures. Furthermore, multi-scale numerical modeling approaches and life cycle assessments (LCA) are highlighted. The findings demonstrate that ceramic-concrete composite inks offer an optimal nexus between structural integrity, automated buildability, and circular economy metrics for resilient, next-generation urban infrastructure.

KEYWORDS: 3D Concrete Printing; Ceramic-Concrete Composites; Rheology & Buildability; Industrial Ceramic Waste; Interfacial Transition Zone; Sustainable Construction; Geopolymers.