The IDONIAL technology center, within the framework of the Metabuilding Labs project, has achieved a significant milestone in the integration of additive manufacturing within the construction sector. The project focuses on the development of green facade panels for the ROOM 2030 initiative, offering an advanced, scalable, and environmentally friendly technical solution.
Although the industry began exploring 3D printing with concrete more than a decade ago, this technology faces critical barriers, such as low resistance to lateral loads and restrictive regulations due to uncertainties about its mechanical performance. In response to these challenges, IDONIAL has opted for the use of technical thermoplastic materials that allow for high resolution and geometric detail in the manufacture of molds or direct-to-construction parts.
For the ROOM 2030 panels, ASA (Acrylonitrile Styrene Acrylate) was initially selected. This material stands out for its excellent resistance to UV degradation and its low moisture absorption, surpassing other polymers such as PLA or ABS.
The design of these panels is not merely aesthetic; their primary function is to collect rainwater for the efficient irrigation of plants integrated into a "green wall." After various tests, a circular design was chosen, optimizing the surface finish and allowing for complete customization during installation. It also incorporates functional channels and perforations for vegetation growth.
The most disruptive advancement of the project has been the transition from conventional FDM technology to BAAM (Big Area Additive Manufacturing). While manufacturing a single panel using traditional methods required five days, the use of BAAM machinery developed by IDONIAL has reduced manufacturing time to just three and a half hours per unit, representing a 95% improvement in production efficiency.
This optimization has been made possible thanks to:
Large-format machinery: A three-axis printer with a working volume of 1200 x 1200 x 1500 mm.
Composite materials: The use of carbon fiber reinforced ASA, which provides greater structural rigidity, dimensional stability, and resistance to deformation.
Specific redesign: A new "cup-type" geometry that ensures continuous and stable material deposition.
Beyond technical efficiency, the project stands out for its commitment to the circular economy. The thermoplastic nature of the panels allows the material to be recycled and reprocessed at the end of its useful life, minimizing environmental impact. With this solution, IDONIAL demonstrates that large-scale additive manufacturing is a viable and robust tool for the challenges of modern architecture.
The Metabuilding Labs project has been funded by the European Union’s Horizon 2020 Research and Innovation Programme, under Grant Agreement No. 953193.
