Bridging 3D-Printed and Cast Concrete: A Review of Mechanical Bond Behavior, Composite Action, and Sustainable Protective Structures
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New possibilities in digital construction are made possible by the combination of 3D printed concrete with traditional cast concrete, which allows for the quick fabrication of hybrid structures that blend structural efficiency, customization, and geometric intricacy. The mechanical bond behavior and composite action at the interface between cast concrete and 3D printed concrete, however, continue to be significant obstacles influencing the overall performance, longevity, and structural integrity of such hybrid systems. In order to clarify the interfacial mechanisms driving load transmission, failure modes, and bond strength development, this thorough study examines current developments in experimental techniques and numerical modeling approaches. Additionally, the research examines how printing parameters, interface preparation methods, and reinforcing tactics can improve composite activity. At the same time, the assessment assesses the application and design of 3D printed concrete for protective constructions, such as—including blast-resistant barriers, disaster shelters, and impact-absorbing walls—highlighting their performance under extreme loading conditions. Through a comparative analysis of existing findings, I identify research gaps, standardization needs, and future directions for optimizing mechanical synergy in hybrid 3D printing systems. Visual summaries including comparative tables, bond stress–slip relationship charts, and schematic illustrations of interface mechanisms are provided to facilitate deeper understanding. This review contributes to the foundation for the next generation of high-performance, sustainable, and rapidly deployable concrete structures.
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