Design, Multi-Scale Structural Analysis, and Construction of Modular Prefabricated 3D-Printed Concrete Residence (2025-12)¶

Residential building construction is increasingly challenged by labour shortages and limited funding. Modular prefabricated 3D printing concrete (3DPC) technology, integrated with digital design and automated construction, offers an efficient and standardised solution to the construction of residential buildings, and has seen emerging applications worldwide. This paper presents the process from architectural and structural design based on one digital model to 3D printing and assembly of a modular prefabricated 3DPC residence, incorporating a multi-scale numerical simulation method for structural analysis. The study identifies the primary limitation of modular 3DPC as the size constraints imposed by printing and transportation equipment. A case study in Hebei Province, China, demonstrates the practicality. Results indicate that under the most unfavourable conditions, the maximum stresses are within 1.3 % of the limit values, ensuring a high safety margin. The 3DPC residence demonstrates time and cost savings, with digital design optimizing coordination among structural, architectural, and MEP systems.