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Manufacture of Concrete Masonry Units01:27

Manufacture of Concrete Masonry Units

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The process of manufacturing concrete masonry units begins by mixing stiff concrete composed of Portland cement, aggregates, and water. This mixture is then poured into metal molds. To ensure the concrete settles uniformly and to avoid separation of its components, the mixture in the molds is subjected to vibration. Shortly after, the still-wet blocks are removed from the molds and placed on racks.
These wet blocks are then transported for curing, which can occur in one of two environments: a...
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Additive Manufacturing of Functionally Graded Ceramic Materials by Stereolithography
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Hybrid Formative-Additive Manufacturing.

Nathan C Brown1, Jochen Mueller1

  • 1Department of Civil and Systems Engineering, Johns Hopkins University, Baltimore, 21218, USA.

Advanced Materials (Deerfield Beach, Fla.)
|April 28, 2025
PubMed
Summary
This summary is machine-generated.

This study introduces a hybrid manufacturing method combining 3D printing with casting to overcome speed limitations in additive manufacturing (AM). This approach enables faster production of complex, multifunctional objects without compromising quality.

Keywords:
3D printingdirect ink writingmaterial extrusionnon‐Newtonian materialsrheology

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Area of Science:

  • Manufacturing Engineering
  • Materials Science
  • Additive Manufacturing

Background:

  • Material extrusion additive manufacturing (AM) offers design flexibility but faces speed limitations due to voxel size constraints.
  • Fabricating complex, multifunctional objects with AM is challenged by the trade-off between resolution and production speed.

Purpose of the Study:

  • To develop a hybrid formative-additive manufacturing technology addressing the scalability challenges of traditional AM.
  • To combine the speed of formative methods with the complexity and flexibility of additive methods.

Main Methods:

  • 3D printing complex geometries and bounding walls for large volumes.
  • Rapidly filling printed structures using casting or molding techniques.
  • Precisely controlling material rheological properties for high interfacial strength and eliminating AM flaws.

Main Results:

  • Achieved exponentially faster production speeds for objects with diverse feature sizes.
  • Eliminated common AM defects such as bulging and internal voids.
  • Enabled fabrication of complex geometries and multimaterial features.

Conclusions:

  • The hybrid formative-additive approach successfully integrates the benefits of both manufacturing paradigms.
  • This novel technology offers a scalable solution for producing intricate, high-quality objects at accelerated rates.