Evaluating 3D-Printed ABS and Carbon Fiber as Sustainable Alternatives to Steel in Concrete Structures

This study evaluates the potential of 3D-printed acrylonitrile butadiene styrene (ABS) and carbon fiber (CF) as sustainable alternatives to steel reinforcement in cement-based materials. The experimental program analyzed the compressive strength of cement pastes and concrete cylinders incorporating 3D-printed ABS and CF elements. Unreinforced cement pastes exhibited higher compressive strength than reinforced pastes, indicating limited reinforcement-matrix interaction. In concrete cylinders, ABS reinforcement increased compressive strength by approximately 3 to 7 MPa compared to steel, whereas CF reinforcement showed variable performance and did not consistently surpass the control specimens. ANOVA and Tukey tests confirmed the statistical significance of the results. The anisotropic response of ABS and CF, inherent to layer-by-layer deposition, was identified as a major factor influencing structural performance, particularly with respect to reinforcement orientation. The results indicate that ABS presents potential as an environmentally favourable alternative to steel in selected applications, while CF requires further optimization for compression-oriented use. Continued research is recommended to evaluate long-term durability, environmental resistance, and reinforcement-matrix compatibility in order to advance the implementation of polymer-based, additively manufactured reinforcements in construction materials.