Dive Brief:
- Researchers with the University of Nevada in Reno are experimenting with a process to help the U.S. Army 3D print structures, including bridges and buildings, in active combat zones, according to a Dec. 3 news release from the university.
- The team’s program, which began in early 2024, involves testing bridging infrastructure assembled with printed 3-foot-long, Lego-like concrete modules, per the release.
- Most experiments with 3D-printed materials are conducted by trial and error, according to the school. In contrast, the research team numerically simulated the bridge — a computational technique to analyze real-world systems through mathematical models, or calculations that run on a computer — in addition to physically testing the structure.
Dive Insight:
The project’s ultimate objective is to provide the Army with a solid technical basis on how to print and assemble structures in the field, including in combat zones where other resources might not be readily available, according to Assistant Professor Floriana Petrone, who is leading the study.
Modular bridges have long been a viable solution for quick fixes in the wake of natural disasters, such as hurricanes. But those components usually need to be shipped to a location. The advantage of the university’s approach is that it would allow teams to print sections quickly onsite.
The university’s approach uses printed components in the shape of Ls and Ts that connect to each other with cables and don’t need specialized equipment, according to the release. The segments could theoretically be disassembled into their component parts when they no longer are needed. Once that happens, the bricks can be reassembled into new configurations.
“Everything could be assembled manually on site,” Petrone said in the release.
The team trialed seven concrete segments held together with post-tensioned cable running through the center of the components, which held an increasing amount of load. The narrow section of bridge supported up to 7,000 pounds, according to the release.
The project is unique due to its combination of 3D-printing, segmental construction and advanced numerical simulation, according to the university. Together, those aspects provide a basis for building what it calls reliably sound, scalable structures.
“The integration of numerical modeling with 3D printing and segmental construction provides a powerful tool for predicting structural performance before construction even begins,” said Sherif Elfass, an associate research professor and team member, in the release. “This allows engineers to optimize the placement of segments and the design of printed components, ensuring that printed structures meet the necessary strength and durability requirements in a variety of conditions.”
The researchers collaborated with the U.S. Army Engineer Research and Development Center Construction Engineering Research Laboratory, and were supported by the U.S. Department of Defense, per the article. The project is funded through June 2025.
