Computational design optimization and thermal assessment of 3D printed prefabricated wall components.

3D printing is a cutting-edge technology that provides a variety of benefits including design flexibility and the opportunity to experiment with different non-conventional geometries. With this consideration, the main objective of this investigation is to design, simulate, and assess the thermal performance of clay 3D-printed prefabricated wall components. To accomplish this, a parametric and algorithmic approach was employed, and a comprehensive methodology was established, with the final aim of being validated, scaled, and replicated. It has been already proved that Additive Manufacturing (AM) technology has important advantages compared with traditional technologies since it represents an efficient and flexible, low-cost, energy and material-saving process, among many other positive characteristics. It is also important to mention that, since one goal is to measure this technology from a sustainable point of view, it also reduces the environmental impact due to both embodied and operative energy demand. The workflow used was made with a performance-based design approach. First, the geometries were developed through parameters and algorithms, using Grasshopper for Rhinoceros. Then, the geometries are used to simulate its thermal performance through two different tools: one under-development plug-in and an already commercial software. Afterwards, the results are compared to assess the individuals and the best-performing shape was selected to be printed. When the component is already printed, it is prepared to be tested in the laboratory. Lastly, the results and the information obtained are used to validate the simulated model and to draw some conclusions. Several simulations were performed using TRfem, a new and still under-development plug-in for Grasshopper, validated with COMSOL Multiphysics, which is an already well-known tool in the field to assess the thermal behavior of the component. In addition, several experiments were performed to characterize the printing process and to understand and optimize the printing process. After analyzing the simulated results, the best-performing component was chosen to be printed (B13_1). Finally, an experimental assessment of the printed components was done using a Heat Flux Test with a LaserComp Fox 600, to validate the before-mentioned simulated model. The results of this investigation confirm the validity of the workflow and prove that it can be replicated and scaled. This implies that other 3D prefabricated building components can be designed and assessed through thermal simulations with the tools above mentioned. Therefore, it can be stated that AM is an evolving and fast-growing technology, that has the potential to make prefabricated and non-prefabricated large-scale components, adding substantial benefits concerning conventional methods, such as avoiding thermal losses, using local materials, optimizing the use of resources, and minimizing the time and cost of the building process.