3D Printing of a Multi-Performative Facade (2024-11)¶

This study investigated the feasibility of 3D printing a multi-performative facade system with recycled thermoplastic. Two custom panels, measuring 1.6 by 2 meters, were computationally designed, and manufactured with mono-material extrusion. The panel design was an iterative process by incorporating a multitude of fabrication parameters and environmental performances into one geometry. The panel manufacturing process was evaluated for geometry accuracy, print path accuracy, overhang, inner layer adhesion, and adhesion to the print bed. Subsequently, real-world building application testing in a facade test rig identified the air permeability, water tightness, resistance to wind loads, and impact resistance performance. The panels passed standardized serviceability and safety standards for wind load resistance and achieved a maximum E5 class for impact resistance. The structural strength values were 1500 Pa for serviceability, 2250 Pa for safety load, and 3262 Pa for breaking load. These findings show that 3D printed designs can integrate multiple performances within a mono-material facade system. They display how freeform geometries can be fabricated in a monolith material with multiple functionalities, enabling the potential application of easily recyclable, prefabricated passive systems.