Tutor: Patrick Bedarf

Collaborator: Ayça Senol (ETH Zurich), Dr. Michele Zanini (FenX AG), Dr. Etienne Jeoffroy (FenX AG)

Discrete construction elements, used in low cost architecture, can be designed and produced using high-tech digital fabrication and materials research to be flexible and adaptable to many necessities. This master thesis project presents a contribution of this goal though the design and fabrication of lightweight architectural assemblies that was developed during a 12 week long as part of a larger research endeavour investigating C3DP with mineral foams from recycled waste, which could be fabricated in mass, customized and optimized for material-reduction in the building environment. Starting from an early development of the tailored print material, designs for interlocking foam modules were systematically explored. As a final demonstrator, we fabricated a lightweight composite facade panel generating thermal comfort, natural light and ventilation playing with the porosity of the elements which can be able to adapt and customize to any necessity. The fabrication method is robotic 3D extrusion-printing and sintering of the materials using an oven. Design contributes to the development of an integrated methodology which includes spatial design, brick design, assembly design and printing tool-path. The main goal of the research is to explore design challenges for 3D printing with mineral foams. This research highlights the benefits of using mineral foams in C3DP for innovative lightweight architectural elements and a conclusive outlook discussing the challenges and future avenues for research.