Fresh-State Characteristics of Geopolymer Mortars for 3D Printing: Mix Design, Rheology and Early-Age Performance

The successful application of extrusion-based 3D-printed geopolymer mortars largely depends on precursor chemistry, activator composition, mixture proportions, and fresh-state behavior, which is highly sensitive to time-dependent structural build-up. This review examines the relationships among mix design, geopolymerization chemistry, rheological properties, and printability requirements for 3D-printed geopolymer mortars. Particular emphasis is placed on the effects of precursor type, alkaline activator characteristics, liquid-to-solid ratio, additives, and fibers on flowability, yield stress, viscosity, extrudability, buildability, shape retention, and interlayer bonding. The review further discusses how geopolymerization kinetics influence the evolution of fresh-state properties, the printable time window, and the transition from extrusion to structural stability. In addition, early-age performance is evaluated in terms of setting behavior, green strength development, and layer-interface integrity. Current challenges, including the lack of standardized test methods, limited comparability among published studies, and the complex coupling between material design and process parameters, are also highlighted. Finally, the review identifies key research gaps and proposes future directions for developing robust, printable, and sustainable geopolymer mortar systems for additive manufacturing in construction.