Prefabricated Connections for Hollow-Core 3D Printed Facade Elements

Abstract

Prefabricated highly insulating glass facades are difficult to disassemble or recycle due to the varying lifespans of their components and offer limited customization possibilities. In contrast, 3D-printed facades (3DPF) allow for bespoke designs and local climate adaptation. Combining sustainable materials like timber and dry construction methods with large-scale 3DP of recycled polymers, such as rPETG, is a promising alternative to traditional prefabricated facades in terms of circularity and façade customization. For large-scale 3DP, the recent development of Hollow-Core 3DP (HC3DP), offers unique possibilities for efficiently fabricating large-scale 3DP building components. However, the integration of HC3DP panels in facade applications remains unexplored. This paper investigates postprocessing methods, detailing, and construction solutions for applying pre-fabricated single-pane HC3DP components in non-load-bearing facades. To achieve this, small-scale experiments were conducted to evaluate construction techniques, including heat-flattening, taping, and polymer welding. Medium-scale tests focused on refining the HC3DP process. Construction detailing is achieved by combining prefabricated standard mullions with dry connections and post-processed HC3DP panels. The study provides a first approach for fabricating, postprocessing, and implementing HC3DP panels as reversible customizable facade components.