3D printing promises to transform architecture forever – and create forms that blow today’s buildings out of the water

New materials are rare in architecture.

Wood, concrete, and masonry have been the foundations of most structures on Earth for centuries.

In the 1880s, steel frames were adopted. architecture forever. Steel made it possible for architects to design taller buildings that had larger windows. These skyscrapers are what define cities today.

Since the industrial revolution construction materials were largely limited to a few mass-produced elements.

This standardised collection of parts covers everything you need, from steel beams and plywood panels to steel beams. Design Construction of buildings for more than 150 years.

That may soon change with advances in what’s called “large-scale additive manufacturing.” Not since the adoption of the steel frame has there been a development with as much potential to transform the way buildings are conceived and constructed.

Large-scale additive manufacturing, like desktop 3D printingIt involves layering objects one at a time. Whether it’s clay, concrete or plastic, the print material is extruded in a fluid state and hardens into its final form.

As director of the Institute for Smart Structures at the University of Tennessee, I’ve been fortunate to work on a series of projects that deploy this new technology.

Although some roadblocks still prevent widespread adoption, I can see the future when buildings are made entirely of recycled materials, or materials sourced locally, and with forms inspired from the geometries found in nature.

Promising prototypes

One of them is the Trillium Pavilion. It’s an open-air structure that was printed using recycled ABS polymer.

The structure’s thin, double-curved surfaces were inspired by the petals of its namesake Flower.

The students designed and printed the project at Loci Robotics. It was then constructed at Cherokee Farm, University of Tennessee in Knoxville.

Another example of large-scale additive production is Tecla. This prototype dwelling measuring 450 square feet (41.8 m2) was designed by Mario Cucinella Architectures. It was printed in Massa Lombarda (a small Italian town).

Tecla was printed by the architects out of local clay. River. This unique combination of inexpensive material and radial geometry resulted in an energy-efficient alternative housing.

Back in the US, the architecture firm Lake Flato partnered with the construction technology firm ICON to print concrete exterior walls for a home dubbed “House Zero” in Austin, Texas.

This home measures 2,000 square feet (185.8 square metres) and demonstrates 3D-printed concrete’s speed and efficiency. The structure has a striking contrast between its curvilinear walls, and its exposed timber frame.

Planning

Three knowledge areas are required for large-scale additive manufacturing: digital design, digital fabrication, and material science.

First, architects design computer models for all components that will be printed. The software can be used by these designers to determine how the components will react to structural forces, and to adjust the components accordingly.

These tools can be used to help designers reduce weight and automate design processes such as smoothing complicated geometric intersections before printing.

3D printing in architecture will only become more popular if it finds its niche. Source: Pixabay

Slicer software is a piece of software that converts the computer model to a set instructions for the printer.

You might assume 3D printers work at a relatively small scale – think Cellphone Holders for toothbrushes and cases

However, 3D printing technology has allowed hardware to scale up significantly.

Sometimes the printing is done via what’s called a gantry-based system – a rectangular framework of sliding rails similar to a desktop 3D printer. Robotic arms are becoming more popular due to their ability print in any orientation.

There are also variations in the printing location. While smaller parts and furnishings can be printed in factories for printing, entire houses must be printed on site.

For large-scale additive production, a wide range of materials are possible. Concrete is a very popular material because of its reliability and ease of use.

Clay is an intriguing alternative because it can be harvested on-site – which is what the designers of Tecla did.

Plastics and polymers may have the greatest applications. These materials are extremely versatile and can be formulated to meet many specific structural and aesthetic requirements.

They can also come from organically or recycled materials.

Inspiration from nature

Because additive manufacturing builds layer by layer, using only the material and energy required to make a particular component, it’s a far more efficient building process than “subtractive methods,” which involve cutting away excess material – think milling a wood beam out of a tree.

Even common materials like concrete and plastics benefit from being 3D-printed, since there’s no need for additional formwork or molds.

Today, most construction materials are mass produced on production lines that are intended to produce the exact same components. This process reduces costs but leaves little scope for customization.

Large-scale additive manufacturing eliminates the need for tools, forms, or dies. This allows each part to be uniquely created without any time penalties for additional complexity or customisation.

3D printing in architecture will only become more popular if it finds its niche. (Source: Pixabay). Another interesting aspect of large-scale additive production is the ability to create complex components with internal gaps. This will allow walls to be printed using conduit or ductwork that is already in place.

In addition, research is taking place to explore the possibilities of multi-material 3D printing, a technique that could allow windows, insulation, structural reinforcement – even wiring – to be fully integrated into a single printed component.

I find it fascinating that additive manufacturing, which is based on a slow hardening material, allows you to build layers layer by layer. This mirrors natural processes like shell formation.

This opens up new possibilities for designers, who can implement geometries difficult to create using other construction methods. However, they are very common in nature.

A lightweight lattice of tubes could be made using structural frames inspired by bird bone’s fine structure. Façades that evoke the shapes of plant leaves might be designed to simultaneously shade the building and produce solar power.

Learn from your mistakes

There are many obstacles to large-scale additive manufacturing’s wider adoption despite its many positive attributes.

Its novelty is perhaps the most difficult to overcome. The entire infrastructure is built around traditional construction methods like concrete, steel and wood. This includes supply chains and building codes.

Additionally, digital fabrication hardware can be expensive and it is difficult to learn the design skills required to work with these materials.

3D printing in architecture will only be accepted if it finds its niche.

It will be similar to word processing’s popularity on desktop computers. I believe it will be large-scale additive production that will make it popular.

Its ability to produce highly efficient structural frames may be what it is. I also already see its promise for creating unique sculptural façades that can be recycled and reprinted at the end of their useful life.
It seems probable that a combination of factors will make it possible for future buildings to be 3D-printed in some way.

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