Feasibility of 3D-Printed PLA Meshes in Gypsum Composites: Preliminary Experiments and Insights

The mechanical limitations of gypsum-based composites necessitate reinforcement strategies to enhance their structural performance. This study investigates the feasibility of integrating 3D-printed polylactic acid (PLA) meshes into gypsum composites through a series of preliminary experiments. Various mesh configurations were tested, including different fiber thicknesses, mesh grid sizes, and single- and double-layer applications. The impact of mesh incorporation on bulk density, ultrasonic pulse velocity (UPV), bending strength, and compressive strength was assessed. The results indicate that the inclusion of PLA meshes had a limited effect on bulk density and led to a slight decrease in UPV values, suggesting increased porosity. Although improvements in mechanical properties were anticipated, most specimens exhibited lower bending and compressive strengths compared to the reference specimen. Among the tested configurations, 2 mm thick meshes demonstrated relatively higher performance, particularly in bending strength, with narrow-mesh aperture yielding better results. However, double-layer mesh applications consistently resulted in lower strength values. These findings highlight the challenges associated with integrating 3D-printed PLA meshes into gypsum composites. While the study provides valuable insights into mesh-based reinforcement, further investigations are required to optimize fiber-matrix interactions and enhance mechanical performance. Future research should explore alternative printing parameters, improved adhesion techniques, and hybrid reinforcement approaches to fully exploit the potential of additive manufacturing in gypsum-based composites.