Stress-Guided Corrugated Geometry for 3D Concrete PrintedBuilding Envelopes (2025-10)¶

This research introduces a new computational framework for designing high-performance double-shell building envelopes using 3D Concrete Printing (3DCP). The framework overcomes the constraints of conventional construction by enabling the realization of complex geometries that are critical for optimal structural efficiency. Our approach begins with finite element analysis to capture internal stress distributions under various load conditions. From these analyses, principal stress paths are used to guide the formation of organic geometric patterns through a reaction–diffusion algorithm, which serve as depth maps for corrugation. The resulting double-shell envelope incorporates stress-aligned corrugations with spatially varying depths, enhancing structural integrity while eliminating the need for stiffening infill concrete that typically causes thermal bridging. This method not only offers significant material savings and improved thermal performance but also reveals a visually distinctive, organically inspired façade. The framework is demonstrated to produce an optimized, stress-aligned corrugated flatwall panel under wind loading, where comparative analysis shows a 56% mass reduction compared to a fully flat assembly and an up to 27% reduction relative to a uniform-vertical-corrugation design, validating its structural and thermal advantages.