Researchers at the University of Nevada, Reno, are exploring a groundbreaking method to help the U.S. Army 3D print critical infrastructure such as bridges and buildings directly in active combat zones. This innovative project, which began in early 2024, focuses on creating modular concrete components that can be printed quickly and assembled on-site. These components, shaped like Lego blocks, are designed to form sturdy bridges and structures without requiring the usual transportation of prefabricated materials to remote or high-risk areas.
The research, led by Assistant Professor Floriana Petrone, aims to develop a technical foundation for printing and constructing essential structures in environments where resources are limited. Unlike traditional 3D printing experiments, which often rely on trial and error, the team at the University of Nevada uses advanced numerical simulations alongside physical tests. These simulations use mathematical models to analyze and predict how the structures will perform in real-world scenarios. This computational approach is a significant step forward, offering a deeper understanding of how printed materials behave under various conditions, which is crucial for military and emergency applications.
The team’s focus is on creating modular concrete bridge segments that can be assembled quickly on-site, providing an alternative to the lengthy and resource-heavy process of transporting and assembling prefabricated infrastructure. Traditional modular bridges, often used in disaster relief efforts, require shipment to the location and specialized equipment for assembly. The University of Nevada’s approach, however, eliminates the need for such resources. The modular sections, which are designed in the shapes of Ls and Ts, interlock using post-tensioned cables running through the middle of each component. These connections ensure structural integrity without the need for advanced machinery. The segments can be disassembled and reused when no longer needed, offering a sustainable solution for temporary military or disaster relief infrastructure.
During the trials, the team tested seven concrete segments, progressively loading them to assess their strength and durability. The narrow section of the bridge was able to support up to 7,000 pounds, demonstrating the effectiveness of the design. This promising outcome suggests that the 3D-printed structures could withstand the stress and weight typically encountered by traditional bridges and buildings.
What makes this project unique is the integration of three advanced technologies: 3D printing, segmental construction, and numerical simulation. The combination allows engineers to predict the performance of a structure before it’s even built, ensuring that it meets the required strength and durability standards. This predictive capability also helps optimize the placement of the segments and the design of the printed components, making the structures more efficient and reliable.
The research is being conducted in collaboration with the U.S. Army Engineer Research and Development Center Construction Engineering Research Laboratory, with funding from the U.S. Department of Defense. The project is scheduled to continue through June 2025, with the goal of making rapid construction in the field a viable and reliable option for the military.
