The construction industry is undergoing a transformative shift towards sustainable, adaptable, and digitally driven practices. One such innovation is the integration of granulated cork into 3D-printed lightweight mortars. Recent investigations explore the viability and benefits of using cork in 3D printing technologies for building applications, as detailed by Rangel et al. (2024).
Printing setup of cork mortar (CR100) consisting of an extruder attached to the print head of a robot arm.
Source: Rangel et al. (2024) from journal Construction Magazine and Building Materials
Material Design and Performance
The research focused on designing a lightweight mortar mix containing granulated cork and cement-based matrices, tailored for extrusion-based 3D printing. Cork’s low density, thermal insulation capacity, and renewable origin made it an ideal aggregate for reducing both environmental impact and material weight.
Through rheological and mechanical assessments, the cork-based mortars demonstrated excellent extrudability, shape stability, and buildability - critical for successful layer-by-layer printing. The natural elasticity of cork also contributed to the mix's flexibility, reducing brittleness and improving post-printing handling.
Sustainability and Environmental Impact
Cork is a renewable, recyclable, and biodegradable material sourced from cork oak bark without harming the tree. Its incorporation into 3D-printed structures reduces the carbon footprint and promotes circular construction principles. The study confirms that using cork aggregates in place of synthetic or mineral fillers substantially reduces the environmental impact of printed mortars.
Additionally, the cork-enhanced mortars retained strong thermal insulation properties, enabling the fabrication of energy-efficient building components directly from the printer - minimizing waste and post-processing.
Applications and Future Potential
The cork-cement composite was successfully printed into wall elements and panels, demonstrating structural coherence and insulation efficacy. This opens avenues for prefabricated housing, emergency shelters, and low-carbon architecture in areas vulnerable to climate extremes.
3D printing with cork represents a sustainable innovation in the construction sector. The ability to create thermally efficient, fire-resistant, and environmentally friendly building components directly through additive manufacturing positions cork-based mortars at the forefront of ecological construction technologies.
Reference
Rangel, C.M., Silva, A., Pereira, A., & Faria, P. (2024). 3D printing lightweight mortars with cork to improve thermal efficiency in buildings. Journal of Building Engineering, 96, 107237.
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