Binder jetting 3D printing in civil engineering: materials, process optimization, and structural applications

Binder jetting 3D printing (BJ3DP) underscores the frontier of additive manufacturing in civil engineering due to diverse applications, high precision and high cost-effectiveness. It is especially acclaimed for its viability to produce delicate interior architectures and suspension elements, such as thin-shell structures and hollow structures, without engagement of support or mold. This review systematically synthesizes the current research landscape of BJ3DP in civil engineering, with a focus on the fundamental principles governing the implementation process, especially for fabrication of complex geometries with interior architecture, pertaining to material compatibility, optimization of process parameters, enhancement of structural performance. The review also addresses existing technological limitations and proposes avenues for future research. Furthermore, BJ3DP has demonstrated successful application in the customized fabrication of architectural ornamentation, geological models, and lightweight structural elements. Nevertheless, practical engineering applications of BJ3DP in civil engineering is hindered by several challenges. Future research endeavors should prioritize investigations into multi-material compatibility, the development of intelligent process control methodologies, and the establishment of a comprehensive framework for performance evaluation to facilitate practical engineering application of BJ3DP in automation construction.