Without a doubt, 3D printing is emerging as a focal point in architectural exploration and construction. With its capacity for limitless creation, it holds the potential to disrupt traditional construction methods and timelines. In this context, additive manufacturing at least in theory, offers the possibility to craft architectural components that can be integrated into a unified, holistic design. Material can be deposited with freedom, without limitations on modulation constraints. The embedded intelligence now achievable in walls enables them to meet the majority of classic architectural demands with ease, addressing aspects such as structural integrity, environmental response, sustainability and economics. 

In contrast, our contemporary understanding of architecture perceives it as a composition of various components, building systems and catalog solutions. We tend to view buildings and structures as assemblies of different elements and materials that each offer solutions to different requirements to create interior spaces. 3D printing has the potential to challenge this view by offering the possibility to design and fabricate seamless components that can resolve multiple classic architectural needs, occasionally exceeding the performance of conventional layered construction systems.

A primary objective of Phase 2: Research involves determining the viability and design of walls with embedded climatic performances, whether they are part of a porosity approach, involve a change in mass,  alter structural capabilities or modify surface aspect of prints. In most of these cases, a mono-material approach will be employed to reconceptualize these variations with a unified, holistic design that has the possibility to offer performance gradients. 

In practice, extrusion-based additive manufacturing methods encounter limitations and challenges due to gravitational forces acting during the production process, some of them critical. The viscous rheology necessary for successful extrusions doesn’t always allow in-situ consolidation in earth 3D printing, forcing it to incorporate it in the design . This leads to inevitable challenges when attempting to deposit large quantities of material when trying to span over horizontal distances, limiting some of the theoretical freedom that the technology offers ab initio.

Other vital concepts such as material shrinkage, bead consolidation and adhesion, or the need for external scaffolding must be considered for successfully realizing porous and gradient 3D printed walls. 

Topic of work 

2024-25 3DPA Phase 2: Research will focus on designing, printing and evaluating complex walls that respond to environmental criterias. Wall discontinuities, produced by the application of gradient approaches to geometry will be the challenges that students will encounter after learning about infill creation and deformation during Techne W05 – Fragments.

Diana De Rada, Mahaveer Bothra, Theo Dattola

This phase initially aims to integrate wall thickness into the previous explorations of Techne w04/05/06 and challenge the limits of gravity within our specific additive manufacturing process, as mass will have a direct effect on the infill loops. In the second and most important stage, through physical experimentation, we will set aside any preconceived expectations regarding the wall performance, as the physical properties will be always tested. Our initial ideas and intuitions will necessitate in-depth, focused, and direct research to assess its veracity. 

We will be experimenting with clay and printing on a smaller scale for evaluating geometries and later on, we will use the industrial robots and earth to print at a larger scale and assess real-world performances. 

We will be working in primary three areas that need development and knowledge gathering for our 1:1 January proto, focusing our efforts on the concept of climatic performance associated with:

1. Structural transitions and reinforcements
2. Surface and wall porosity
3. Thermal conditions and climate

All research projects are expected to incorporate as well, development in areas such as: design for additive manufacturing, material advancements and weight reduction, updates to extrusion processes, prefabrication concepts and off-site construction, wet-state actuations and insertions, and lastly, application of specific computational developments and workflows.

Research encompasses a methodology that includes articulating a problem, formulating a hypothesis, gathering facts and data, analyzing the facts, and arriving at certain conclusions. These conclusions may present as solution(s) to the identified problem or as generalizations for theoretical formulation. The research process can validate—or refute—preconceived ideas about specific topics. In our scenario, students will be tasked with conducting thorough work to assess their research outcomes, create knowledge through each experimental loop and test print before making any assumptions. With this method, we will ensure that all of our decisions are based on evidence. 

We’ll be utilizing research-through-design methodologies and applying knowledge-on-action practices. This involves reflection on action – essentially, taking a moment to think about what we’ve done after doing it, evaluating our actions and outcomes, and then formulating the next iteration loop for advancing the research forward. 

Activating Play. Rob Tieben. 2015

Students will work in groups to achieve the goals of the Research Studio. Following classical learning by experimenting methods and design-driven innovation, students will be asked to demonstrate their hypothesis via exploration, mostly through prototyping and sensor evaluation. Each group will have access to a desktop printer to conduct their small-scale (1:10) research and prototypes (Students will be autonomous with the usage of these printers and its maintenance) and access to the ABB robot (1:2/1:1) with the help of superlab assistants. For the evaluation and assessment of performances, students might be required to develop their own validation methods via prototypes, test beds, sensors, etc. 

3dPA students will need to develop these experimental setups within IaaC facilities, in both physical and digital to validate and demonstrate their research agendas, taking into account the limitations and restrictions we might face. 

Physical Analysis 

Existing experimental setups in-house: 

• Geometrical Deformation (with Calliper or 3D scanning / Photogrammetry)
• Water content (with precise scale)
• Dripping test (visual quality + Weight loss)
• Compressive / Flexural Strength analysis (with crash test) 
• Thermal analysis (with Thermal camera, laser measurements)
• Heat Chamber (with heat lamp and temperature sensors)
• Light Analysis (with camera and light sensors) 

…

Digital Analysis

Digital analysis and simulation: 

• Geometrical Analysis (Gh) *

• • Rainwater simulation (Gh) *

• Sun Analysis (LadyBug) *

• Structural Analysis (Karamba) **

• Light Analysis (Render / Honey Bee) **
• CFD analysis (Rhino CFD, Autodesk CFD) *** 

* Easy 

** Medium complexity

*** High complexity

Throughout the six weeks of research, follow-up sessions are set for Tuesdays and Fridays for Research and Wednesdays for Matter Research. During this period, there are also planned several pills in Computational to assist students with specific topics.

Students will have access to support hours to discuss both physical and digital topics. Additionally, tutors will be available for extra 1-on-1 sessions during crucial or critical moments. However, the recommendation for students is to maximize the value of the review sessions by coming prepared each time with a concise presentation of the work achieved in the past days, along with a proposal for the following week’s tasks, identifying any potential doubts or questions that might arise during the proposed development process. In that manner, we will focus our efforts to keep the research project always up to date. 

Learning Objectives

At course completion the student will:

1. Formulate a research question and research agenda in an innovative field (related with 3DP). 
2. Develop scientific research through design.
3. Learn to define and use validation methods, both digital and physical.
4. Interpret data from testing and propose decisions taken by data analysis. 
5. Extrapolate conclusions that could be used in a larger-scale architectural design. 
6. Document and present research findings.