Material characterization and structural behaviour of HC3DP elements for lightweight facades

This paper investigates the structural behavior and material characteristics of Hollow-Core 3D printing (HC3DP) for large-spanning elements. The study compares HC3DP with conventional large-scale Material Extrusion (ME) methods and explores the influence of varying thermal boundary conditions on the mechanical properties of the 3D printed polymer. In total three types of experimental procedures are presented. Tensile experiments, 3 PT bending tests, and finally, 4 PT bending tests of large-scale beams are conducted. The research highlights the potential of HC3DP in architectural applications, particularly in the construction of high-performance, site-specific facades. The findings underscore the importance of planning and design for the 3D printing process, emphasizing the critical role of printing direction in determining the structural behavior and performance of 3D printed facade elements. Additionally, the paper presents a theoretical model for calculating for the maximum spanning distance of 3D printed facades, based on the results obtained from the experiments presented. The results demonstrate that HC3DP is a promising technology for facade construction, enabling the fabrication of aesthetically unique and material efficient 3DP facades with a better structural capacity then comparable conventional ME methods.