Alternative Silica Aerogel Mortar for Improving Energy Efficiency, Thermal Comfort, and Environmental Performance in Residential Buildings Under Hot-Dry Climates Using 3D Additive Manufacturing (2026-01)¶

Reducing the environmental impact of building energy consumption is a global priority, particularly given that air conditioning systems account for up to one-third of worldwide energy demand. One effective strategy for enhancing building energy efficiency is the incorporation of materials with advanced thermal properties into building envelopes. In this context, silica aerogel (SA), characterized by its extremely low thermal conductivity, offers significant potential to reduce heating and cooling loads in both hot and cold climates. This study evaluates a novel cementitious mortar incorporating SA and industrial by-products, applied through 3D additive manufacturing. A conventional concrete block house was modeled and compared to a version constructed with SA-based mortar using DesignBuilder and EnergyPlus simulations for an extreme hot-dry climate. Results show that 3D-printed walls with SA reduce thermal energy demand by 42–44%, with the greatest impact on heating. Annual HVAC energy consumption decreases by up to 51%, lowering the specific demand to 118 kWh/m2 below the regional average. This translates into electricity cost savings of up to 54% under a basic tariff. Furthermore, CO₂ emissions are reduced by 33%, equivalent to 63 kg CO₂/m2 annually. The novelty of this research lies in combining an aerogel-based insulating mortar with additive manufacturing technology (3D printing), evaluated under severe hot-dry conditions. Findings highlight its potential to improve energy performance and sustainability in residential buildings located in arid regions.