A Conceptual Model for Building Artistic and Geometrically Complex Building Envelopes Using Concrete 3D Printing (2025-08)¶

In pursuing a carbon–neutral future, traditional construction methods are increasingly criticised for their high pollution levels, safety hazards, and wasteful practices. While prefabricated and modular construction offers partial solutions, they often limit architectural expression and remain niche segments. This paper discusses a conceptual model that epitomises automation and art inspired by the architectural genius of figures like Antoni Gaudi. The objective is to develop an integrated approach that merges architectural and structural engineering design stages into a single iterative process, incorporating structural shape optimisation, material selection, cost considerations, aesthetics, and sustainability. Leveraging additive manufacturing, specifically 3D printing, allows for fabricating highly customised and complex geometries, accommodating diverse architectural styles. This research explores and enhances topology optimisation techniques for pattern-based generative design in building architecture and individual structural component-based design. The design procedures involve density-based and thickness-based optimisation using isogeometric and finite element analysis, implemented in the open-source platform OPS-ITO. To overcome the limitations of 3D printing large-scale complex shapes as a single unit, the finalised geometric designs are divided into multiple components for efficient factory manufacturing and on-site assembly, enhancing quality control. Two model-scale prototypes, an igloo structure and a structurally optimised prestressed bridge beam, demonstrate the feasibility and intricacies of the design, optimisation, fabrication, and assembly cycle for geometrically complex building envelopes. The insights obtained from these prototype build-ups are further documented to explore the feasibility and intricacies of the design, optimisation, fabrication, and assembly cycle for geometrically complex building envelopes.