Testing the Edge | 3D Printing with Extra-Wide Layers

Pushing the Boundaries of Concrete Printing

At Vertico, we’re constantly experimenting to see how far we can take our technology. In this test, we doubled our standard nozzle size to explore the limits of thick-layer printing. While our usual layer width is about 3 cm, this print pushed the boundaries to 8 cm wide and 13 mm high, dramatically increasing the amount of concrete extruded per pass.

Fine-Tuning for Precision

Printing at this scale isn’t as simple as swapping out the nozzle. We had to adjust multiple parameters, from pumping speed to robotic motion, to ensure both stability and precision. At the start of the video, you can see the original print speed in action. Look closely at the lower section of the wall, and you’ll notice some uneven layers, the visible result of trial and error as we honed in on the perfect settings.

Why Layer Height Matters

Beyond aesthetics and structural performance, experimenting with layer height is essential for non-planar printing. When printing along sharp angles, a higher layer height combined with faster movement can help avoid over-extrusion, ensuring a cleaner, more controlled result.

Learning by Testing

Projects like this are about more than just impressive prints, they’re opportunities to identify challenges and figure out how to overcome them. By testing the extremes of our system, we gain valuable insights that translate directly into better, faster, and more versatile 3D concrete printing in real-world applications.

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