Interview Making 3D Printing of Concrete Safer

he Amarteja Kocherla is a structural engineering researcher from India with a deep interest in structural health monitoring, smart sensors, and digital construction. He is currently a Marie-Skłodowska-Curie-Fellow at BAM. In this interview, he talks about his research journey, the challenges and motivations behind his work, and how he aims to make 3D concrete printing safer and smarter through innovative sensor technologies.

Why did you choose BAM for your fellowship?

I previously received BAM’s Adolf Martens Fellowship, and that experience left a lasting impression on me. The collaborative culture at BAM, its strong scientific environment, excellent facilities, and interdisciplinary environment made returning for my Marie Curie Fellowship a natural step in my research journey.

What is your current research project about, and why is it socially or technologically important?

My project, InSenS-3DCP, focuses on making 3D concrete printing safer, faster, and more reliable. In 3D concrete printing, the process consists of several stages: mixing, pumping, deposition, and hardening. Each stage requires careful control to ensure that the printed structure remains stable and strong. If these conditions are not well balanced, the quality or safety of the printed element can be affected.

Through a collaboration between the divisions Non-destructive Testing Methods for Civil Engineering and Technology of Construction Materials, BAM has an advanced setup using inline sensors to monitor material behavior during pumping and to verify layer geometry post-deposition. My work builds on this by embedding small piezoelectric (PZT) sensors directly into the printed concrete. These sensors can assess the internal condition of printed concrete structures in real time through tiny changes in their vibration behavior or changes in received stress waves that indicate cracks, voids, or material degradation.

Combining data from both inline and embedded sensors helps us better understand changes in the material during pumping and post-extrusion and allows us to use this knowledge to automatically fine-tune the printing process. This approach makes 3D concrete printing more consistent, efficient, and reliable, which is an important step toward using this technology for safe and sustainable construction in the future.

What inspired you to apply for a Marie-Sklodowska-Curie Fellowship, and what advice would you give to other researchers considering applying for this fellowship?

The MSCA fellowship is one of the most respected fellowships in Europe, and offers the chance to grow professionally, connect with leading scientists, and build a strong foundation for future academic or industry roles. The freedom to design and lead my own project while contributing to a broader research community was especially motivating.

I also received great support from BAM during the application process. They have a dedicated team that helps researchers apply for funding and provides guidance along the way. From improving the structure of my proposal to helping me communicate the impact of my work, their feedback helped strengthen my application.

For researchers who are thinking about applying, my advice would be to start early and take time to shape your idea carefully. Share your proposal with mentors and colleagues and be open to feedback. Most importantly, focus on clarity. Make sure your proposal tells a clear story, so that even someone outside your field can understand why your research matters.

What have been your biggest challenges so far – scientifically or personally – and how did you overcome them?

One of the biggest challenges for me has been moving to a new country with a toddler. Everything felt new at once. The work culture was different, the language was unfamiliar, and even simple things like understanding product labels at the supermarket took extra effort. I was settling into a new research environment while also learning how to navigate daily life in a language I did not speak.

Learning German, staying open to support, and finding a balance between research and parenting with my partner helped us gradually settle in. It’s still busy at times, but it feels more manageable now.

If you had to describe your research in one sentence for the general public – what would it be?

I am building smart sensors that allow concrete 3D printers to check their own work as they build and to monitor the structure’s health over time.