Additive manufacturing on the façade: functional use of direct metal laser sintering hatch distance process parameters in building envelope

Abstract

Purpose The purpose of this article is on the functional usability of metal additive manufacturing (AM) direct metal laser sintering (DMLS) production technology process parameters in the construction industry. In the study, the advantages of thermal optimization and weight reduction in the case of the use of foam metals obtained by changing the hatch distance the production process parameter, in the production of facade panels in the architectural field are revealed. Design/methodology/approach The methods in the study; production of the small scaled facade panels with nine different hatch distance parameters, determination of the thermal change with the infrared thermography method, microstructure examination, weight measurement. Findings The paper lays the groundwork for the manufacturability of lighter and lower thermal conductivity facade panels by changing the hatch distance parameters. Within the scope of the study, the definition of semi-open-cell foam aluminum and the product screening strategy offers innovation. Within the scope of the study, this scope is shared as an algorithmic summary. In addition, the study offers a new perspective within the scope of multiple optimizable panel production in facade panels with AM technology. Originality/value Hatch distance parameter change was first discussed in this study in the architectural field, and a semi-open cell foam aluminum panel was obtained with the scanning strategy determined within the scope of the study. This panel geometry, which is defined as semi-open cell foam aluminum, can be used as a design element by painting or coating the outer surface, it can be stated that it will also provide thermal and weight optimization.

Environmentally Responsive Materials for Building Envelopes: A Review on Manufacturing and Biomimicry-Based Approaches

“…However, there is still a lack of studies showing how the manufacturing process, material selection, and geometry parameters may impact the final performance of the building. These effects have usually been tackled as a single study in which the material and manufacturing techniques have been analyzed regarding the effects of such parameters [ 161 , 166 , 188 ].…”

“…AM capabilities of improving sustainability and reducing environmental impact have been widely addressed in the literature, in which automation and digital design show an opportunity to reduce material use and errors, positively impacting the environment [ 156 , 157 , 158 , 159 , 160 ]. Because of this, together with the geometric flexibility offered by this fabrication method, AM can answer some issues and difficulties encountered when designing and implementing active and regenerative envelopes, playing an active role in architecture and future energy-efficient solutions when compared with traditional manufacturing techniques [ 28 , 161 ].…”