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A review of 3d printing technology-the future of sustainable construction

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DOI: 10.1016/j.matpr.2023.08.013

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Materials Today: Proceedings xxx (xxxx) xxx

Contents lists available at ScienceDirect

Materials Today: Proceedings


journal homepage: www.elsevier.com/locate/matpr

A review of 3d printing technology-the future of sustainable construction


Toiba Tabassum a, Ajaz Ahmad Mir b, *
a
Amity University, Noida, Uttar Pradesh 201313, India
b
Dr B R Ambedkar National Institute of Technoloy Jalandhar, Jalandhar 144027, India

A R T I C L E I N F O A B S T R A C T

Keywords: The construction industry has traditionally been slow, labour-intensive, and faced challenges in sustainability.
3D-printing However, recent advancements in 3D concrete printing (3DCP) offer promising solutions for faster, more precise,
Sustainability and sustainable construction practices. This critical review examines the developments and advances in 3D
Recycled
printing of concrete, as well as the challenges and future potential of this technology in sustainable construction.
Eco-friendly
Concrete
Our study highlights the advantages of 3D printing technology, such as reducing costs, materials, and time,
enhancing safety, and minimizing environmental pollution. Moreover, 3D printing enables the creation of
complex and intricate designs that were previously challenging to achieve through traditional methods. To
address sustainability concerns, we explore eco-friendly alternatives like high-volume fly ash, geopolymers, and
recycled glass aggregates that can be utilized in 3D printing. These materials not only reduce environmental
impact but also enhance the long-term strength performance of building components. While discussing the
different 3D printing methods, including extrusion and powder-based techniques, we emphasize the potential
applications of each method in sustainable construction. In conclusion, 3D printing technology has the potential
to transform the construction industry by offering low-cost, efficient, and environmentally responsible solutions.
However, challenges like job implications and structural stability must be addressed through further research.

1. Introduction construction, thus making the process more sustainable. Traditional


construction methods often result in a significant amount of waste, as
The construction industry has been one of the least technologically materials are cut to size and assembled on-site [9–11]. In contrast, 3D
advanced industries in the world, characterized by slow, labour- printing technology can reduce waste by producing building compo­
intensive, and time-consuming processes. However, recent advance­ nents with greater precision, using only the necessary amount of mate­
ments in 3D concrete printing (3DCP) have opened up new possibilities rial. Additionally, 3D printing technology can use sustainable materials,
for faster, more precise, and more sustainable construction practices. such as recycled plastic or biodegradable materials, which can reduce
Traditionally, constructing a building or infrastructure involves multiple the carbon footprint of the construction industry [12–14]. Furthermore,
stages, including designing, procuring materials, and assembling. This 3D printing technology has the potential to revolutionize the design and
process is time-consuming and labour-intensive, and the construction functionality of structures. With 3D printing, it is possible to create
industry has been plagued with delays, cost overruns, and safety con­ intricate and complex designs that would be difficult or impossible to
cerns [1–4]. Although, 3D printing technology can potentially revolu­ achieve using traditional construction methods [15–18]. 3D printing
tionize the construction industry by significantly reducing the time and technology allows architects and engineers to develop strategies that
labour required to build structures. One of the key benefits of 3D incorporate curves, angles, and intricate details, leading to visually
printing in construction is the speed and precision of the process. Unlike stunning and functional structures. Four examples of vertical 3DP in
traditional construction methods, which require manual labour, 3D architecture. Fig. 1 represents four applications of vertical 3DP,
printing technology can create complex and intricate shapes with including (a) an in-situ wall with a shell and fills application, (b) a solid
incredible speed and accuracy. This can result in faster construction geometry component, (c) a panel component, and (d) in-situ walls and
times, reduced labour costs, and more efficient use of resources [5–8]. columns. These images highlight the potential of vertical 3D printing in
The 3D printing technology can reduce the waste generated during creating complex structures with high precision and efficiency.

* Corresponding author.
E-mail addresses: gid.ajaz@gmail.com, ajazam.ce.21@nitj.ac.in (A. Ahmad Mir).

https://doi.org/10.1016/j.matpr.2023.08.013
Received 26 April 2023; Received in revised form 29 July 2023; Accepted 3 August 2023
2214-7853/Copyright © 2023 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the UKIERI Concrete
Congress – ‘Sustainable Concrete Infrastructure.

Please cite this article as: Toiba Tabassum, Ajaz Ahmad Mir, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2023.08.013
T. Tabassum and A. Ahmad Mir Materials Today: Proceedings xxx (xxxx) xxx

Mehar et al. (2020) emphasized that the rapid advancements in 3D leading to customized specifications. With manufacturing facilities
printing have revolutionized the use of concrete as a 3D printable ma­ closer to consumers, the process becomes more flexible, responsive, and
terial [19]. Kothman and Faber (2016) pointed out the significant quality-controlled while reducing the need for global transportation
manufacturing benefits of 3D-printed concrete, including shorter lead through fleet tracking technology, thus saving energy and time [28].
times, integrated functionalities, and reduced material usage, which This technology finds wide applications in agriculture, healthcare,
could potentially streamline the construction supply chain and minimize automotive, and aerospace industries, fostering mass customization and
logistical efforts [20]. Despite its advantages, the adoption of 3D open-source designs [29].
printing in construction has been slower compared to other industries, However, adopting 3D printing technology in manufacturing also
as noted by Wu et al. (2018) [21]. Teizer et al. (2016) highlighted the presents certain challenges. Notably, it may reduce demand for
importance of public awareness in driving construction companies to manufacturing labor, potentially impacting economies reliant on low-
explore alternative construction processes utilizing 3D printing [22]. skilled jobs. Additionally, the accessibility of 3D printing for diverse
However, Jakus (2019) suggested that the rapid proliferation of 3D objects, including dangerous items like guns, raises security concerns.
printing was influenced more by crucial legal and social events/groups Restrictions on its use may be necessary to prevent misuse by terrorists
rather than a significant technological breakthrough [23]. and criminals. Furthermore, the ease of generating 3D objects from
In line with sustainable development goals, Johnston (2016) stressed blueprints increases the risk of counterfeiting, demanding measures to
the need for relevant information and awareness about sustainable address intellectual property concerns [30].
practices and lifestyles by 2030 [24]. Oke et al. (2018) emphasized the In the past few decades, technology has developed faster and faster.
significance of government support, affordable digital tools, robust in­ The objects manufactured daily are getting smaller, and the cost is
formation systems, technology awareness, and local research and getting lower [31]. As the industrial revolution began, the growth po­
development to strengthen digital technology and foster collaboration tential of construction methods was much slower and did not keep pace
[25]. Increased global awareness and exaggerated claims about the ca­ with other aspects of human life. It is only now that while constructing
pabilities of 3D printing have led to its swift adoption in academic and buildings, environmental preservation is recognized and considered
clinical research institutions. As a result, 3D printing has not only [32–35]. 3D printing helps to reduce the pollution of the environment by
become an essential tool for existing research but also a subject of reducing the emission of greenhouse gasses and also reduces construc­
research itself [23]. tion costs [36]. It can significantly improve the efficiency and safety of
3D printing technology, stemming from layer-by-layer fabrication of the work and can also significantly shorten the construction time.
3D structures based on computer-aided design (CAD) drawings, has Although this technology is more prevalent in developed countries, its
emerged as an innovative and versatile technology platform[26]. It of­ necessity and influence in India are quite desirable [37]. In architecture,
fers promising opportunities for companies seeking to enhance 3D printing uses different terms, such as rapid prototyping, desktop
manufacturing efficiency and can print various materials, including manufacturing, automated manufacturing, and layered manufacturing
thermoplastics, ceramics, graphene-based materials, and metals [27]. [38].
The adoption of 3D printing technology has the potential to revolu­
tionize industries, enabling faster production and cost reduction.
Moreover, it gives consumers more significant input in the final product,

Fig. 1. Illustration of vertical 3D printing applications. The merged images exhibit (a) a vertically printed in-situ wall with shell and fill application, (b) a solid
geometry component printed vertically, (c) a vertically printed panel component, and (d) vertically printed in-situ walls and columns. These visual representations
demonstrate the capabilities of vertical 3D printing in producing complex architectural features with strength and precision.

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T. Tabassum and A. Ahmad Mir Materials Today: Proceedings xxx (xxxx) xxx

1.1. Current applications of 3D printing technology in construction construction method is subtractive, while 3D printing is an additive
manufacturing (AM). AM involves various techniques as Fig. 2 shows the
3D printing technology is already used in various applications within most commonly used techniques of AM in each process. It should be
the construction industry, such as building and infrastructure con­ noted that it is the material used in each process that entirely forms the
struction, customized components, concrete printing, and repairs and base of this classification [49–53].
maintenance. The technology has enabled faster and more precise con­ The comprehensive review thoroughly examines the developments
struction, reduced waste, and improved sustainability. With continued and advances in 3DCP technology within the context of sustainable
advancements and increased accessibility, we can expect to see even construction. A distinctive feature of our review is its focus on sustain­
more innovative applications of 3D printing technology in construction ability aspects, exploring eco-friendly materials such as high-volume fly
[9,39,40]. ash, geopolymers, and recycled glass aggregates that have the potential
to revolutionize sustainable construction practices. Additionally, we
1.2. Advancements in 3D printing technology conduct an in-depth analysis of different 3D printing methods, including
extrusion and powder-based techniques, highlighting their advantages,
Advancements in 3D printing technology have greatly expanded its challenges, and potential applications. Moreover, the review identifies
potential applications in the construction industry. One significant area important research gaps and challenges, paving the way for future in­
of progress is the development of new materials, such as sustainable and vestigations and innovations. Our paper concludes with practical rec­
biodegradable materials, that can be used in 3D printing. Additionally, ommendations, guiding future research and inspiring advancements in
printing techniques have become more precise and efficient, allowing the field. By presenting a comprehensive and focused review empha­
for the creation of larger and more complex structures. Software ad­ sising sustainability, in-depth analysis of 3D printing methods, identi­
vancements have also enabled architects and engineers to create intri­ fication of research gaps, and practical recommendations, our paper
cate designs and simulate the performance of structures before they are significantly contributes to the existing literature on 3D printing tech­
built. Furthermore, mobile 3D printing machines have been developed, nology and its potential in sustainable construction. It will serve as a
making it possible to 3D print structures on-site, reducing transportation valuable resource for researchers, practitioners, and decision-makers in
and assembly costs. As these advancements continue, 3D printing the construction industry.
technology has the potential to revolutionize the way we design and
construct buildings and infrastructure [41–43]. 3. Methods of 3D printing

1.3. Ethical considerations and future implications 3.1. Extrusion method

As with any new technology, 3D printing in construction raises Extrusion capacity is the ability of concrete to flow out of a nozzle. It
ethical considerations that must be addressed as it becomes more is evaluated based on the concrete paste that can be printed without
widespread. One of the most pressing concerns is the potential loss of blocking the nozzle. In addition, the printed concrete paste should be
jobs in the construction industry as 3D printers become more prevalent. free from cracks and separations. Extrudability depends on definite mix
Another ethical consideration is the environmental impact of 3D print­ characteristics and nozzle calibration. If the nozzle is not calibrated
ing, as it requires energy and resources to produce the materials and correctly, the concrete printing will be affected, and the concrete can get
power the machines. There are also questions about the safety and stuck inside the pump tube. Concrete is time-dependent, as a result it
durability of 3D-printed structures, as they have not yet been extensively will affect the entire mix. The structure will fail if the concrete is not
tested over time. Looking towards the future, 3D printing in construction extruded correctly, affecting the bond between the layers. In many
has the potential to improve sustainability significantly and reduce cases, large-gantry machines are used for printing, but this requires a
waste, as well as enable the creation of more intricate and visually very long time to manufacture. So, to avoid time delay for large-scale in-
striking designs. However, widespread adoption of the technology will situ works, the robotic arm was introduced. In order to meet the over­
require a significant investment in research and development, as well as whelming demand for digital extruded concrete, the printing material
new regulations and standards to ensure safety and quality. Addition­ should be thixotropic, quick hydrating, quick setting, dense, and need
ally, there is a need for increased collaboration between architects, en­ well-controlled properties such as yield strength and plastic viscosity
gineers, and construction workers to fully harness the potential of 3D [50]. The printing of complex geometries is complicated, but to over­
printing technology. As the technology continues to develop, it will be come this, various experiments have been carried out, and they have
essential to address these ethical considerations and plan for the future succeeded. In addition, multiple parameters such as “scale, surrounding
implications of 3D printing in the construction industry [39,40]. environment, support and assembly strategy” can be used for digital
concreting, and a classification method has been introduced. The
2. 3D printing technology and additive manufacturing extrusion method is the most widely used in Digital Concreting and is
becoming increasingly popular among many construction companies
The 3D printing process involves the use of digital models for [54–57].
creating 3D physical objects by the superimposition of materials in thin
layers over each other until the entire object is created [44]. In the 3.2. Powder-based 3D printing
construction field, the technology of 3D printing is still in its early days,
but it looks promising. Currently, in the design and construction process, This is also an additive manufacturing process. In this process, ideal
3D printing is gradually but indeed becoming indispensable technology. components are manufactured by extruding liquid binders into a powder
The construction of buildings by 3D printing technique will have a sig­ bed. This liquid binder binds the powder where it strikes the bed. The
nificant impact on time, cost, occupational safety and economic markets lower layer is 3 mm thick, a thin layer of about 0.1 mm of new powder is
[45]. We know two eras of architecture: before the Industrial Revolu­ applied, and the roller smoothest the bed surface. When a particular
tion, during which buildings used to take longer time to build, but after layer is completed, the binder feeder feeds the binder solution into the
the industrial revolution, they became unique and customizable. Mass print head and pushes it out through the nozzle [58]. The workflow of
production speeded up the construction of buildings [36,39,46–48]. the binder solution is the Drop on demand (DoD) process followed by a
However, it leads to losing their uniqueness and customability.3D de-powdering process in which the excess wastes are cleared. The
printing can help us bridge the gap between mass production and cus­ strength and durability can be enhanced by heat treatment or infiltration
tomization. Within a manufacturing setting, the conventional process. The non-extrusion process is an ex-situ method developed for

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T. Tabassum and A. Ahmad Mir Materials Today: Proceedings xxx (xxxx) xxx

Fig. 2. The classification of additive manufacturing.

producing prefabricated concrete parts [59–63]. Non-extrusion, 3D 4.1. High volume fly ash
printing technology is suitable for small-scale components, such as
panels, permanent formworks and internal structures, which can then be Fly ash concrete based on fly ash material is a possible substitute for
connected at the site. To manufacture the formwork, materials based on the printing of sustainable concrete structures. Fly ash is a residue and
cement or non-cement are used. The binder Is squeezed into powder derivative of the coal industry. It carries some harmful metals, which
through the nozzle, binding the powder particles together [64]. After can harm the soil and cause air pollution [59,61]. Therefore, the SC3DP-
suitable work steps have been determined, the components are ready NTU study proposes a formulation of high-volume fly ash suitable for 3D
and can be taken out again after drying for a period of time. Unbound concrete printing applications, which can decrease the environmental
dust can be removed with a blower. Afterwards, the feature is delivered impact instead of recycling in an open environment. It has been proven
to the construction site, assembled and installed. to improve the long-term strength performance of building materials.
Powder-based printing has some limitations. The printer and print­
ing material have restrictions. Compared with the extrusion method, the 4.2. Geopolymers
printer is small or medium. Therefore, the requirement for more sig­
nificant components can be complex. Several factors affect printing Geopolymer is a cement-free binder that can replace OPC and is the
speed. Binder ink jet speed and powder laying speed are the main fac­ result of a polymerization process in which a source of alumina silicate
tors, so they must be parallel to increase the printing speed [65,66]. The (like blast furnace slag or fly ash) is stimulated with an alkaline solution
printing material’s availability is the next issue thixotropic, quick hy­ [69,70]. For example, the consumption and emissions of carbon dioxide
drating, quick setting, dense, and needs well-controlled properties such used in ash-based geopolymers are 60% and 80% lower than that of
as yield strength and plastic viscosity. The printing of complex geome­ OPC, respectively Geopolymers are not only green and sustainable, but
tries is complicated, but to overcome this, various experiments have they are particularly appropriate for extrusion 3D printing because
been carried out, and they succeeded. geopolymers have variable setting characteristics also they are more
durable than OPC.
4. Sustainable construction and sustainable material
4.3. Recycled glass aggregates
Sustainable buildings strive to meet the requirements of today’s
infrastructure, working and living environments, with no compromise Even though the supply of sand from the seabed or from the desert is
on the capability of future generations to satisfy their future needs. Most in abundance, still the world is facing a scarcity of construction sand.
printable cement materials used in extrusion-based 3DCP technology are This is primarily due to the nature of sea sand and desert sand, which are
Portland cement-based binders (OPC). In the production process of OPC, not appropriate for applications in construction, so only river sand can
a large quantity of carbon dioxide (CO2) is released into the atmosphere be utilized for construction[71,72]. Therefore, in the case of limited
[67,68]. Moreover, OPC production consumes a lot of energy. When construction resources, another solution is required to meet the growing
using OPC-based materials, these two factors will affect the robustness of demand.
3DCP. Therefore, there is a need to develop non-OPC materials suitable
for 3DCP-based extrusion processes. Various environmentally friendly 4.4. Advantages, challenges, and applications of 3D printing technologies
materials with low carbon dioxide emissions can be used for 3D printing. in sustainable construction
Fly ash, geopolymers, and recycled glass are environmentally friendly
materials used in industry. Sustainable construction is an increasingly important area of focus as
we seek to address the environmental and social challenges of our time.
3D printing technology offers a promising solution to some of the key

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T. Tabassum and A. Ahmad Mir Materials Today: Proceedings xxx (xxxx) xxx

challenges of sustainable construction, including reducing waste, high cost may make it less practical for large-scale construction projects.
conserving resources, and minimizing the environmental impact of Binder Jetting is a high-speed, low-cost technology with a wide range of
building projects. However, there are numerous 3D printing technolo­ materials, making it suitable for decorative objects and small-scale
gies available, each with its own set of advantages and challenges. models. However, its limited strength and poor surface finish may
Table 1 provides an overview of the most relevant 3D printing tech­ make it less suitable for more functional building components. In sum­
nologies and their potential applications in sustainable construction. By mary, the table demonstrates the advantages and limitations of each 3D
carefully considering the benefits and limitations of each technology, printing technology and highlights their potential applications in sus­
architects and designers can make informed decisions about the most tainable construction. By choosing the most appropriate technology for
appropriate 3D printing technology to use for a given project. With the a given project, designers and architects can take advantage of 3D
right technology and approach, 3D printing has the potential to trans­ printing to create more sustainable and efficient structures.
form sustainable construction practices, enabling the creation of more
efficient, durable, and environmentally responsible buildings 5. Research gaps
[59,73–77].
Table 1 presents an overview of six different 3D printing technolo­ 5.1. Material development and large-scale construction
gies, namely Fused Deposition Modelling (FDM), Stereolithography
(SLA), Selective Laser Sintering (SLS), Powder Bed Fusion (PBF), Ma­ While 3D printing has made significant progress in printing various
terial Jetting, and Binder Jetting. For each technology, the table lists its materials, there is still a need for further research to develop new ma­
advantages, challenges, and potential applications in sustainable con­ terials with improved properties, sustainability, and cost-effectiveness
struction. One of the main advantages of FDM is its low cost and ease of for different applications. Most existing research focuses on small-
use, making it a popular choice for prototyping and small-scale models. scale 3D printing. There is a research gap in exploring and implement­
However, its limited accuracy and poor surface finish make it less suit­ ing 3D printing for large-scale construction projects, such as buildings
able for building components that require high precision and quality. and infrastructure.
SLA, on the other hand, offers high accuracy and an excellent surface
finish. Although, its limited material selection and high cost make it
more suitable for prototyping and concept models rather than large- 5.2. Standardization, regulations and life cycle assessment
scale construction projects.
The SLS offers a broader range of materials and higher strength, The lack of standardized procedures and regulations for 3D printing
making it more suitable for building components and custom parts that in construction hinders its widespread adoption. More research is
require durability and structural integrity. However, the high cost and needed to establish industry standards and guidelines to ensure quality,
complex process make it less accessible and practical for smaller-scale safety, and compatibility with existing construction practices. There is a
projects. PBF also offers high accuracy and strength, but it is limited need for comprehensive life cycle assessments of 3D printed structures
material selection and complex process may present challenges for some to evaluate their long-term environmental impact, including factors
projects. Material Jetting technology offers high accuracy and excellent such as material sourcing, energy consumption, and end-of-life disposal.
surface finish, as well as a wide range of materials, making it suitable for
building components and architectural models that require intricate 6. Challenges
details and high-quality finishes. However, its limited build size and
6.1. Structural integrity, durability and scalability
Table 1
The advantages, challenges, and applications of 3d printing technologies in Ensuring the structural integrity and durability of 3D-printed com­
sustainable construction. ponents remains a challenge. The layer-by-layer printing process can
Technology Advantages Challenges Applications
introduce weaknesses and inconsistencies in the material, requiring
further research to enhance overall performance. Scaling up 3D printing
Powder Bed Fusion High accuracy, Limited material Building
for large-scale construction poses challenges regarding printing speed,
(PBF) excellent selection, high components,
strength, large cost, complex complex material flow control, and logistical constraints. Overcoming these
build volume process structures, custom challenges is essential for successful implementation in the construction
parts industry.
Material Jetting High accuracy, Limited build Building
excellent surface size, high cost, components,
finish, wide range post-processing architectural
of materials required models, small-
6.2. Cost-effectiveness, workforce skills and training
scale objects
Binder Jetting High speed, low Limited Building Despite its potential advantages, 3D printing technology can be cost-
cost, wide range strength, poor components, prohibitive, especially for small-scale projects. Identifying cost-effective
of materials surface finish, decorative
approaches and optimizing the use of materials is critical to making 3D
post-processing objects, small-
required scale models printing more economically viable. Workforce Skills and Training: The
Fused Deposition Low cost, simple Limited Prototyping, adoption of 3D printing in construction requires a skilled workforce
Modeling (FDM) to use, accuracy, low small-scale capable of operating and maintaining 3D printing machines. Bridging
compatible with a speed, poor models, building the skills gap and providing adequate training is crucial for successful
wide range of surface finish components
materials
integration.
Stereolithography High accuracy, Limited material Prototyping,
(SLA) excellent surface selection, high concept models, 7. Future scope
finish cost, low speed architectural
models
Selective Laser Wide range of High cost, Building 7.1. Integration with AI and automation integrating
Sintering (SLS) materials, high complex components,
accuracy, process, post- custom parts, 3D printing technology with artificial intelligence and automation
excellent strength processing structural can revolutionize the construction process, enabling autonomous and
required elements
adaptive construction systems.

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T. Tabassum and A. Ahmad Mir Materials Today: Proceedings xxx (xxxx) xxx

7.2. Customization and mass customization CRediT authorship contribution statement

3D printing has the potential to enable mass customization, allowing Toiba Tabassum: Conceptualization, Data curation, Writing –
structures to be tailored to specific requirements without compromising original draft. Ajaz Ahmad Mir: Investigation, Supervision, Conceptu­
efficiency and cost-effectiveness. Exploring the possibilities of custom­ alization, Writing – review & editing.
ization in various applications is a promising avenue for future research.
Declaration of Competing Interest

7.3. Sustainable materials The authors declare that they have no known competing financial
interests or personal relationships that could have appeared to influence
Future research should focus on developing sustainable and eco- the work reported in this paper.
friendly materials suitable for 3D printing. The incorporation of recy­
cled or bio-based materials can significantly reduce the environmental Data availability
impact of 3D printed structures.
No data was used for the research described in the article.

7.4. Multi-material printing Acknowledgement

Advancements in multi-material 3D printing can open up new pos­ We would like to express our gratitude to each other for our team­
sibilities for complex and multifunctional structures that combine work and collaboration on this review paper. We would also like to
different materials with distinct properties. acknowledge the valuable feedback and support which significantly
contributed to the completion of this manuscript.
8. Conclusion
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6
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