Digital Twin for 3D Concrete Printing

Project Overview

Rationale

This project implements three main stages of a digital twin. First stage (Digital Master) is a BIM workflow for automatic generation of a LOD 400. Second stage (Digital Shadow) is a parametric workflow for multi-robot collaboration (MRC) for automatic placing of printing supports for wall penetrations. Third stage (Digital Twin) is a parametric workflow for multi-robot intelligent inline inspection (MRi³) system.

Impact

Streamline the workflow for automatic generation of a BIM data repository enriched with G-Code parameters enabling customization of printing strategy.
Reduce human intervention for placing printing supports required for wall gaps without interrupting printing process or requiring human exposure to moving parts of industrial robot printer.
Improve safety and quality by eliminating subjective human interpretation of printing quality and replacing it with a robotic system capable of intelligent inline inspection that measure printed layers geometry in real time with a computer vision system.

Publication List

Journal Papers

Rojas, J., Trout, D., Earnest, S., and Hasanzadeh, S. (2026) “Occupational Safety and Health Considerations In 3D Printing Construction”. Journal of Management in Engineering, DOI: 10.1061/JMENEA.MEENG-7383
Rojas, J., Hasanzadeh, S. (2025) “An Integrated BIM Planning Workflow for 3D Concrete Printing Projects” Journal of Computing in Civil Engineering., 39(5), DOI: 10.1061/JCCEE5.CPENG-6188

Conference Proceedings

Rojas, J., and Hasanzadeh, S. (2026). “4D-5D Additive Construction: Integrating 4D and 5D Simulations into 3D Concrete Printing Construction”. Proc., Construction Research Congress 2026, Accepted.
Rojas, J., and Hasanzadeh, S. (2026). “Quality Inspection of Additive Construction: A Parametric Approach for Automated Scanning of 3D Printed Walls”. 2026 Proceedings of the 43rd ISARC, Singapore, Accepted.
Rojas, J., and Hasanzadeh, S., (2025). “Human Factor in 3D Concrete Printing for Construction”. Proc., 69th Hum. Factors Ergon. Soc., International Annual.
Rojas, J., and Hasanzadeh, S., (2025). “Parametric Teleoperation and Machine Control for Collaborative Work in 3D Concrete Printing”. In Computing in Civil Engineering 2025, American Society of Civil Engineers, New Orleans, LA.
Rojas, J., Braul, A., and Hasanzadeh, S., (2025). “Perceptions of 3D Printing Construction Adoption in Latin America: Opportunities, Barriers, and Strategies for Sustainable Infrastructure.” Proc., CIB Conferences, Vol. 1, Article 113.
Rojas, J., and Hasanzadeh, S. (2024). “A Unified Workflow for Enhanced Efficiency in 3D Concrete Printing Using 6DoF Robotic Arm”. In Computing in Civil Engineering 2024, American Society of Civil Engineers, Pittsburgh, PA.
Rojas, J., and Hasanzadeh, S. (2024). “Novel Digital Twin Architecture for 3D Concrete Printing in the AEC Industry”. Proc., Construction Research Congress 2024, pp. 1337-1346.