Sovetova, Meruyert
(2025)
Thermal performance of 3D-printed buildings.
PhD thesis, University of Nottingham.
Abstract
3D printing in construction offers a sustainable alternative to conventional methods, with advantages such as geometric flexibility, reduced waste, cost and time savings. However, the high costs associated with large-scale 3D printers constrain the widespread adoption of additive manufacturing in construction. This research addresses this limitation by designing, calibrating, and evaluating an affordable lab-scale 3D printer tailored for cement-based materials, aiming to lower the entry barriers for additive manufacturing research in construction.
A systematic literature review revealed that while many studies have explored the benefits of 3D printing in construction, the thermal and energy performances of 3D-printed structures remain underexplored. To address this gap and provide a holistic understanding of the heat transfer properties of 3D-printed structures, this study presents a multi-scale analysis of the influence of the 3D printing process on thermal performance. At the microscale, this study investigates the impact of printing parameters on the thermal conductivity and defect development in 3D-printed concrete structures. Experimental techniques, including heat flow meter analysis, scanning electron microscopy, and infrared imaging, were employed to assess the thermal properties and microstructure of 3D-printed samples. The findings reveal that printing parameters significantly impact porosity, void formation, and microstructural characteristics, affecting thermal performance. At the component scale, the thermal performance of 3D-printed wall segments was experimentally analysed using a hot box apparatus. The results indicate that strategic cross-section design can improve thermal performance, potentially reducing material consumption while eliminating the need for additional insulation. Thermal transmittance values ranged from 1.94 to 2.64 W/m²K, depending on cross-section design and testing orientation. At the macro-scale, the study evaluated the impact of wall design on the thermal performance of a whole building under urban wind and cold climate conditions using Computational Fluid Dynamics (CFD) modelling, validated with wind tunnel experiments. The results demonstrate that cross-section design significantly influences temperature distribution, thermal bridge formation, and convective heat transfer coefficients (CHTC). Heat flux values at the windward surface varied between 9.38 and 59.19 W/m² across different wall designs. Some wall designs effectively minimised heat loss; the wall design with continuous air gap exhibited the lowest heat transfer values and achieved more uniform temperature distribution and CHTC, demonstrating superior performance. The findings highlight the significant influence of wind speed and direction on heat flux and CHTC, reinforcing the importance of wind orientation in designing thermally efficient building envelopes.
This study provides a multi-scale analysis of the thermal performance of 3D-printed structures, revealing that printing parameters and geometric design significantly influence thermal performance. The findings support the development of environmentally friendly construction practices and promote the broader adoption of additive manufacturing in the building sector.
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