Early-age 3D printed concrete structures are inherently unstable because their low initial strength makes freshly deposited layers vulnerable to deformation and collapse before setting. After extrusion, the material exhibits limited load-bearing capacity and is highly sensitive to accumulated stresses from subsequent layers.

To address this challenge, we apply a quantitative simulation framework that predicts when and how failures initiate and propagate during printing. By reproducing the failure process virtually, the framework allows us to evaluate buildability in advance,
define safe operating windows and systematically optimize printing protocols. This simulation-driven approach ultimately transforms failure prediction into practical guidance for 3D concrete printing process control and design, enabling more reliable and automated construction with fresh concrete.