Development of 3D rapid prototyping system for large-scale physical modeling of complex rock masses and engineering structures with case study analysis
JIANG Quan1*, LIU Qiang2, ZHANG Shishu3, DU Shigui4
(1. State Key Laboratory of Geomechanics and Geotechnical Engineering Safety, Institute of Rock and Soil Mechanics, Chinese Academy of Sciences, Wuhan, Hubei 430071, China; 2. State Key Laboratory of Safety and Resilience of Civil Engineering in Mountain Area, East China Jiaotong University, Nanchang, Jiangxi 330013, China; 3. PowerChina Chengdu Engineering Corporation Limited, Chengdu, Sichuan 611130, China; 4. Institute of Rock Mechanics,
Ningbo University, Ningbo, Zhejiang 315211, China)
Abstract：Similar physical model tests in geotechnical engineering encounter significant challenges, particularly in accurately representing complex stratigraphic structures, engineering geometries, and structural plane morphologies. Conventional industrial 3D printing techniques often fail to meet the specific requirements of geotechnical modeling. To address this gap, we have developed a three-dimensional rapid prototyping system designed for fabricating large-scale similitude physical models of complex rock masses and engineering structures. This system employs a dual-nozzle pumping extrusion molding method and incorporates technological innovations in several key areas, including the pumping system, extrusion system, and dual-nozzle switching system. These advancements effectively resolve critical issues such as the extrusion of high-viscosity printing materials, material overflow during dual-nozzle switching, and frequent clogs during extended printing sessions. Functional tests demonstrate that the equipment can rapidly fabricate physical models of complex rock masses and engineering structures using multiple materials, exhibiting high forming precision, excellent printing compactness, fast printing speeds, straightforward disassembly, and ease of cleaning. Subsequently, the device was utilized to produce rock-like specimens containing weak interlayers and tunnel physical models with interlayer structures. Case study analyses confirm that the system effectively meets the demands of physical model testing in geotechnical engineering, providing valuable technical support for innovations in rock mechanics theory and the safe construction of infrastructure engineering projects.
江 权1*，刘 强2，张世殊3，杜时贵4. 复杂岩体与工程结构大型相似物理模型三维快速成型设备研制及实例分析[J]. 岩石力学与工程学报, 2026, 45(3): 668-683.
JIANG Quan1*, LIU Qiang2, ZHANG Shishu3, DU Shigui4. Development of 3D rapid prototyping system for large-scale physical modeling of complex rock masses and engineering structures with case study analysis. , 2026, 45(3): 668-683.
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2026, Vol. 45 
