3D Printing and Topology Optimization of Building Envelope

This research examined how 3D printing with thermoplastics can revolutionize building envelopes by incorporating topology optimization for wind loads into the design process. The project, part of the Plastic Architecture exhibition at Copper Union in New York, explores the potential for large-scale additive manufacturing technologies to transform the high-performance building facade industry. The study presents topology optimization as a design method that, when combined with 3D printing, enables the creation of material-efficient, geometrically complex building envelopes. The focus was on producing a lightweight yet strong building envelope that could withstand wind and gravity loads. Through functional integration and optimization, future facade systems are expected to have improved thermal and structural performance while being faster and easier to produce and install.