Influence of Extruded Filament Shape on Buildability in 3D Concrete Printing: A Geometry-Informed Deep Learning-FEM Approach
Authors: Giacomo Rizzieri, Saif-Ur-Rehman, Jörg F. Unger, Annika Robens-Radermacher
Abstract
The geometric morphology of deposited filaments can significantly influence the structural performance and stability of 3D concrete-printed (3DCP) structures. However, most finite element (FEM)-based approaches for buildability assessment represent printed layers as simplified rectangles, potentially limiting predictive accuracy. This study proposes a geometry-informed modelling framework that integrates the deep-learning-based filament shape prediction tool ShapeGen3DCP with a layer-activation FEM approach to investigate the effect of realistic filament geometries on buildability. The framework generates geometry-aware numerical models directly from material and process parameters, eliminating the need for experimental filament characterization or computationally intensive fluid-flow simulations. Validation against experimental data and a parametric study of rectilinear walls demonstrate that extrusion parameters and the resulting filament geometry can significantly influence buildability predictions. Realistic filament representations are particularly important for free-flow deposition, whereas layer-pressing strategies are less sensitive to geometric simplifications. Among the investigated representations, an elliptical approximation provides an effective balance between geometric fidelity and modelling simplicity. When rectangular representations are preferred to enable regular computational meshes for faster simulations, defining their dimensions based on volume conservation improves prediction reliability compared with calibrating them using either the maximum filament width or the interlayer contact width. Overall, the proposed methodology demonstrates the importance of incorporating filament geometry into 3DCP simulations and provides practical guidance for selecting efficient and accurate geometric representations for buildability assessment.
Recent advances in 3D mesh generation have enabled the creation of visually realistic assets. However, much of their visual fidelity is encoded in textures rather than geometry. When such assets are fabricated using monochromatic materials, texture information is largely lost, causing visually important details to disappear even when the original geometry is faithfully preserved. A key challenge is that the geometric perturbations required to recover texture-dependent appearance cues often introduce sharp local features and high-frequency surface structures, which may increase stress concentration and fabrication risk. In this paper, we present GenMF, an appearance-oriented geometry refinement framework for monochromatic fabrication. GenMF transforms texture-dependent visual cues into geometry-induced shading effects and formulates geometry refinement as a balance between appearance preservation and fabrication-oriented robustness. To discourage structurally and narrow the gap between simulation and physical manufacturing, we further introduce a differentiable stress-aware regularization based on a learned thermal-stress predictor. Experimental results demonstrate that GenMF significantly improves appearance preservation under monochromatic rendering while reducing stress concentration under a consistent thermo-mechanical simulation setting. Physical 3D printing examples further show that the refined geometries preserve more recognizable visual details while remaining suitable for fabrication. These results suggest that appearance-aware geometry refinement provides an effective bridge between generated 3D assets and fabrication-ready monochromatic objects.
Generating physically buildable brick structures from 3D shapes requires more than geometric reconstruction: the output must also satisfy discrete part constraints and structural stability. Existing brick generation methods either rely on heuristic optimization, which can break down when the target 3D shape does not admit a feasible structure under predefined constraints, or generate brick sequences without explicitly modeling the underlying 3D geometry and assembly relations. In this work, we present BrickAnything, a geometry-conditioned autoregressive framework for generating buildable brick structures from diverse 3D representations. BrickAnything uses point clouds as a unified geometric interface and predicts brick sequences that reconstruct the target shape under assembly constraints. To model structural dependencies among bricks, we introduce a structure-aware tree tokenization, which represents brick structures through local attachment relations. This formulation makes sequence generation more consistent with the physical construction process, and reduces invalid intermediate states. We further introduce preference-based alignment post-training, validity-constrained decoding and adaptive rollback to improve buildability objectives such as stability and geometric fidelity. Extensive experiments demonstrate that BrickAnything produces geometrically faithful and physically realizable brick structures, and that the proposed tokenization effectively reduces rollback and regeneration compared with conventional ordering strategies.
Traditional sheet metal forming relies on time-consuming and expensive Finite Element Analysis (FEA) for design validation, a process that significantly prolongs design cycles. While surrogate models offer faster iteration, current approaches have limitations: scalar-based methods cannot capture comprehensive field-based FEA results, while existing image-based models often ignore the critical role of material properties by focusing solely on geometry. To address this gap, we develop a physics-guided deep learning framework, namely StampFormer, which simultaneously uses component geometry and material stress-strain responses to predict FEA outcomes. The StampFormer framework uses three core components to process data. A Material-Augmented Geometric Network (MAGN) first fuses geometric and material data. This information is then integrated at various levels by a Hierarchical Material Embedding Injection Unit (HMEIU) before being processed by the primary network backbone, an adapted Swin-UNet. We evaluated our model on the stamping of a crossmember panel with two simulation datasets for steel and aluminium panels, and results demonstrate that StampFormer provides high-fidelity predictions of critical physical fields - including thinning, major strain, minor strain, plastic strain, and displacement - in under a second. Compared with ground truth FEA, our model achieved an average relative error of less than 8.5% on the four 2D fields and a mean squared error of less than 1.2 mm2 for the 3D displacement field. In summary, we introduce a practical and efficient framework that integrates multimodal information, namely geometry and material properties, to provide fast and accurate predictions, enabling designers to perform real-time manufacturability assessments.