3D Printed PLA Geometry Drives Structural Performance in Concrete Beams
A research team led by Dr. Muhammad Talha Junaid at the University of Sharjah tested cement mortar beams reinforced with FDM-printed PLA profiles. The study found that surface geometry was the dominant variable, with the best-performing configuration reaching nearly 80% of steel’s bending strength and matching its ductility. Concrete on its own handles compression well but fails under tension. For more than a century, steel rebar has filled that gap, valued for its ability to resist tensile forces, bond reliably with the surrounding matrix, and maintain stiffness under load. The downside is persistent: steel is heavy, and in environments where moisture and chloride ions can reach it through the concrete cover, it corrodes, expanding as it does, cracking the structure from within. Coastal and marine construction, as well as infrastructure salted against ice, all face this problem as a routine maintenance challenge.
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