Petruzzi Elena, Tsamis Alexandros, Ullal Chaitanya
CASE, School of Architecture, Rensselaer Polytechnic Institute, Brooklyn, New York, USA.
Material Science and Engineering, Rensselaer Polytechnic Institute, Brooklyn, New York, USA.
3D Print Addit Manuf. 2025 Apr 14;12(2):131-140. doi: 10.1089/3dp.2023.0356. eCollection 2025 Apr.
Large-scale extrusion-based additive manufacturing (AM) has emerged as a potential alternative for construction, addressing the challenges associated with the high carbon footprint of the building industry. Although AM enables the creation of intricate design geometries through controlled material deposition, providing innovative solution strategies for design construction, large-scale 3D printed structures are limited to a single homogeneous material, such as cement or clay, and their functionality is restricted to load-bearing formwork. Although still at a nascent stage for building construction, multimaterial additive manufacturing (MMAM) has emerged as a promising technology for the industry to overcome this limitation and reduce the embodied carbon of 3D printed structures by limiting the use of structural materials through topology optimization strategies. MMAM enables the fabrication of functionally graded materials (FGMs) by controlling the extrusion ratio between two or more distinct materials, resulting in building envelopes with multiple performance characteristics and functions. While research has focused on improving the structural performance of 3D-printed envelopes through MMAM, limited attention has been given to optimizing thermal performance and energy efficiency. An increasing interest in thermal energy storage technologies for buildings using the latent heat storage capacity of microencapsulated phase change materials (mPCMs) is related to the advantages of improving energy efficiency using materials that can absorb, store, and release heat when their temperature changes. To this end, this study proposes an FGM design-to-construction methodology for large-scale structures that optimizes the thermal performance of 3D-printed envelopes by locally tuning the distribution of heterogeneous mixes of clay and mPCMs during the AM process. The results of the digital simulations and physical tests show that the local optimization of mPCM and clay within the wall thickness according to the specific temperature differential can provide annual energy reductions compared with a homogeneously printed envelope without embedded mPCM.
基于挤出的大规模增材制造（AM）已成为建筑领域一种潜在的替代方案，可应对与建筑业高碳足迹相关的挑战。尽管增材制造能够通过可控的材料沉积创建复杂的设计几何形状，为设计施工提供创新的解决方案策略，但大规模3D打印结构仅限于单一均质材料，如水泥或粘土，其功能也仅限于承重模板。尽管在建筑施工中仍处于起步阶段，但多材料增材制造（MMAM）已成为该行业一项有前景的技术，可通过拓扑优化策略限制结构材料的使用来克服这一限制，并减少3D打印结构的隐含碳。多材料增材制造能够通过控制两种或更多不同材料之间的挤出比例来制造功能梯度材料（FGM），从而形成具有多种性能特征和功能特征的建筑围护结构。虽然研究主要集中在通过多材料增材制造提高3D打印围护结构的结构性能，但对优化热性能和能源效率的关注有限。利用微胶囊相变材料（mPCM）的潜热存储能力来实现建筑热能存储技术的兴趣日益浓厚，这与使用能够在温度变化时吸收、存储和释放热量的材料提高能源效率的优势有关。为此，本研究提出了一种用于大规模结构的功能梯度材料设计到施工方法，通过在增材制造过程中局部调整粘土和微胶囊相变材料的非均质混合物分布来优化3D打印围护结构的热性能。数字模拟和物理测试结果表明，与未嵌入微胶囊相变材料的均匀打印围护结构相比，根据特定温差在壁厚内对微胶囊相变材料和粘土进行局部优化可实现年度节能。
