Project Title: 

A Computational Design Tool for Additive Manufacturing of Facade Panels based on Life Cycle Thinking

Project Summary: 

This PhD research investigates the transformative potential of 3D printing and computational design workflows in architectural facade panel design, focusing on the product’s thermal performance and circular design principles. Motivated by the increasing urgency for climate action and alignment with the UN Sustainable Development Goals (SDGs), this study addresses the construction industry’s significant contribution to global greenhouse gas emissions (approximately 37%). It challenges the limitations of standardised, mass-produced facades that often fail to consider site-specific environmental conditions or recyclability. The research uses design research methodology to study, develop and tests a computational design tool capable of generating optimised facade panels that integrate thermal regulation and structural performance within internal lattice structures. Using recycled plastics as a primary material, the research explores the feasibility of additive manufacturing for fabricating sustainable, mono-material facade systems designed for disassembly and recycling at the end of their lifecycle. Through iterative prototyping the project evaluates lattice configurations to balance thermal insulation, structural integrity, and material efficiency. The facades will be evaluated using a planetary boundaries life-cycle assessment (PB-LCA) to examine the environmental performance of these novel facade systems in comparison to traditional solutions. By integrating site-specific data and circular economy principles, this research aims to contribute to the sustainable transformation of the construction industry, offering tools and insights that optimise material usage, reduce waste, and advance the integration of sustainable materials and manufacturing techniques in architecture.