PSI - Issue 83

Samia M. Mohamed et al. / Procedia Structural Integrity 83 (2026) 63–71

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4. Conclusions This review examined recent advances in 3D-printed self-sensing cementitious composites, focusing on material design, conductive filler systems, and the integration of sensing functionality with extrusion-based additive manufacturing. Carbon-based fillers such as carbon fibers, carbon nanotubes, graphite, graphene derivatives, and carbon black have been widely used to establish conductive networks within cementitious matrices, enabling strain dependent electrical responses. Hybrid filler systems have shown particularly promising performance, achieving high sensing sensitivity and reduced electrical resistivity. Similarly, CNT-modified cementitious composites demonstrated significant reductions in electrical resistivity and improved crack-related sensing capability. Despite these advances, integrating self-sensing functionality with extrusion-based 3D printing remains challenging due to competing requirements between printability, mechanical performance, and sensing behavior. Conductive fillers can alter rheological properties, affecting extrusion stability and layer deposition, while print induced anisotropy may influence the orientation of conductive networks and the resulting sensing response. Furthermore, structural-scale validation of 3D-printed self-sensing cementitious materials remains limited. Although studies have demonstrated the feasibility of embedding 3D-printed sensors in reinforced concrete beams and printing self-sensing slab elements, long-term durability, signal stability, and real-world performance require further investigation. Future research should focus on integrated mix design strategies, improved conductive filler dispersion, and structural-scale validation of printable self-sensing composites. 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