3D Printing With Cementitious Composites: Innovations, Challenges, and Prospects—A Review

Cementitious composite additive manufacturing is poised to disrupt the industry through its ability to print complex shapes and rapidly produce lightweight structures with improved performance characteristics. The current review provides a systematic and comparative analysis of recent developments in 3D printing technologies, ranging from extrusion printing to binder jetting, powder bed fusion (PBF), contour crafting (CC) technology, and spray‐based systems, in conjunction with modern material formulations including nanomaterials, fibers, bio‐inspired materials, self‐healing agents, and shape memory alloys (SMAs). This work presents the findings in a comprehensive fashion, demonstrating that compressive strength values exceeding 100 MPa, flexural strengths of up to 15 MPa, and enhanced interlayer bonding of up to 40% can be accomplished using optimized material formulations and 3D printing parameters. Critical areas that require further improvement include the development of isotropic mechanical properties, overcoming of weaker interfaces, improved durability, and increased production capacities for large structures. Several research gaps have been highlighted, including standardization issues, multi‐material printing, process automation, and structural monitoring during operation. All things considered, this work provides a comprehensive framework for future studies and practical applications, facilitating the development of high‐performance, environmentally friendly, and multipurpose 3D‐printed cementitious composites (3DPCC).