Weak structural plane deformation is responsible for the non-uniform large deformation disasters in layered rock tunnels, resulting in steel arch distortion and secondary lining cracking. In this study, a servo biaxial testing system was employed to conduct physical modeling tests on layered rock tunnels with bedding planes of varying dip angles. The influence of structural anisotropy in layered rocks on the micro displacement and strain field of surrounding rocks was analyzed using digital image correlation (DIC) technology. The spatiotemporal evolution of non-uniform deformation of surrounding rocks was investigated, and numerical simulation was performed to verify the experimental results. The findings indicate that the displacement and strain field of the surrounding layered rocks are all maximized at the horizontal bedding planes and decrease linearly with the increasing dip angle. The failure of the layered surrounding rock with different dip angles occurs and extends along the bedding planes. Compressive strain failure occurs after excavation under high horizontal stress. This study provides significant theoretical support for the analysis, prediction, and control of non-uniform deformation of tunnel surrounding rocks. (c) 2024 Institute of Rock and Soil Mechanics, Chinese Academy of Sciences. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/ 4.0/).

3D printing has emerged as a revolutionary technique for producing products with specific shapes and mechanical properties tailored to various needs. Its ability to fabricate intricate structures and forms has garnered considerable attention, leading to numerous research efforts exploring its potential benefits in geotechnical applications. These endeavours highlight the possibilities of utilizing 3D printing technology to create innovative and customized materials for soil reinforcement, such as geosynthetics, and fibres, as well as replicating soil particles, physical models of soil structures, and drainage systems in geo-structures. Additionally, beyond its role in geotechnical engineering, the interaction between geo-structures (foundations, retaining walls, embankments, tunnels, piles, infrastructures, etc.) and the surrounding soil under different loading and environmental conditions is of paramount importance. The interface between these structures and the soil plays a critical role in load transfer and overall stability. Therefore, this study focuses on investigating the interface between soil and 3D printed components through direct shear testing. The experimental campaign aims to examine how different factors, including the type of 3D printing materials, material rigidity, and surface texture of the printed components, influence the shear behaviour of the soil-3D printing material interface. The findings suggest that Young's modulus of the 3D printed materials plays a crucial role in determining the response of the soil-3D printed parts interface. Furthermore, an optimized design is proposed to achieve the desired shearing resistance at the interface. The insights gained from this investigation have practical implications for optimizing the design of 3D-printed components in geotechnical engineering applications.