3D printing in architecture

Not only in mechanical engineering, in the aerospace industry, in medicine and in archaeology, but also in architecture 3D printing is increasingly used. In this article, we would like to take a closer look at what additive manufacturing can be used for in architecture and what the main applications are.

Applications

Basically, a distinction is made here between 3D printers that are

  • Produce low-cost architectural models that are used as study models during the subsequent manufacturing process,
  • Produce realistic yet detailed architectural models to visually represent the object and used to promote the project; and
  • itself be used for the production of 3D printed building objects.

Which printing process is best suited?

Fused deposition modeling (FDM) technology is usually used to produce architectural models. Most desktop 3D printers are FDM devices that work with the so-called filament. In addition to the FDM process, stereolithography (SLA) and digital light processing technology (DLP) are also used in architectural 3D printing.

Advantages of 3D printing in the field of architecture

3D printed models are of no small importance as a complement to virtual 3D models and computer simulations. Here, objects are produced as models and can give the viewer a first visual impression. These objects can be produced with 3D printers at low cost and at the same time with high precision. If different versions of a project are to be displayed, this is effortlessly possible with 3D printed models. These models can be shown to the customer, who can thus also get a visual impression during various construction phases.

In addition to the cost savings, the time savings are also a factor that should not be underestimated. Whereas in the past objects had to be created to scale from wood or foam in painstaking manual work that sometimes took days, this can now be done by a 3D printer. All that is required is to enter the relevant data into appropriate 3D software and then transfer the data to the ready-to-use 3D printer via USB cable or SD card. While the 3D printer is working, the architect can pursue another activity.

If changes are to be made to the later object, the 3D model can be specified on the computer and then reprinted. Especially for iterative design, 3D printing is an almost ideal tool.

3D printing also represents a high level of detail and allows the use of many different materials and surfaces. Very often, however, post-processing has to be done. This work includes the removal of supporting materials, cleaning the surface to painting and coloring. In Malaysia, for example – unlike in Hamburg – they have created a miniature wonderland with the MinNature, where most of the building models were made with 3D printers. Here, among other things, you can view entire districts of Kuala Lumpur in miniature.

If 3D printing is done with large concrete printers, it is possible to produce even entire houses, smaller exhibition pavilions, bicycle and pedestrian bridges with this technology. Such houses, pavilions and bridges were built and put to use in Denmark, the Netherlands, Russia and Spain, among others. At Design Miami 2016, visitors could admire a 3D printed pavilion made of bamboo called “Flotsam and Jetsam.”

However, most architects will certainly use 3D printing mainly for visualizing building objects of various kinds. For this purpose, a 3D printer using the FDM process is sufficient in most cases.

Various architectural models

Already in the design phase, it is possible to make different 3D models that correspond to different concepts, for example. Just then you should choose a 3D printer that prints in great detail. The selection of the filament is also of importance that should not be underestimated. Especially for urban models, a large building volume is also important.

What also speaks for 3D printing in architecture?

Another important criterion in favor of 3D printing is the lower production costs. Many concepts can now be tested not only on screen via computer simulation, but as a real object, highlighting potential problems. As a rule, a 3D printer with an extruder is completely sufficient here. Often only one or two types of material are needed (probably ABS and PLA), which should be in stock in a small number of colors. For example, according to Stratasys, one of the leading 3D printer manufacturers, the use of these devices can reduce modeling costs to as much as 75 percent.

Architects can achieve a particularly high level of detail if they use the SLA or DLP method to print the models. These 3D printing processes sometimes work with a resin (resin) and are known for their high level of detail. It is the details that often arouse the interest of investors or customers.

In addition to the 3D printing itself, some other work is of course necessary. This includes the graphic design of the individual objects on the computer with the help of 3D printing software in the preparation time. During the post-processing period, the 3D printer or its build plate may need to be cleaned and the printed object polished, mounted if necessary, and painted.

Manufacturing of complex structures

Architecturally difficult objects can be realized with additive manufacturing. Among other things, this allows sheets and domes to be printed that would be almost impossible to achieve manually. But anyone who thinks that this would make the work of designers or model makers obsolete is probably mistaken. With this technology, they are enabled to realize even more complicated structures. So 3D printing is just one part in the “toolbox” of developers, model makers and designers.

Costs

The manufacturing of 3D printed architectural models can either be done in-house or outsourced to a 3D printing service provider who will make architectural models. If you don't want to outsource these services, you should take a look at the various product reviews that have now been published for many 3D printers – ready-to-use printers or 3D printer kits. In general, the price of a 3D printed object depends on the following parameters, among others:

  • Size of the model to be printed,
  • Desired intensity of details,
  • Material quality,
  • Choice of filaments,
  • Duration of 3D printing (power consumption/electricity costs),
  • Proportionate acquisition costs for the 3D printer.

Size of the model to be printed and duration of 3D printing

The larger the 3D printed model is to be, the more material is consumed and the higher the filament costs rise. The size also affects the printing time. 3D printing larger objects usually takes more time, which drives up the cost of electricity.

Details intensity

Additive manufacturing of a complex and at the same time detailed architectural model takes more time than for a simple object with only a few details. Furthermore, detailed models often require more preparation time.

Material quality

Filaments are quite expensive to purchase, especially if they are to have properties such as UV resistance and flexibility. In any case, do not skimp on the quality of the material, buy quality goods.

Filament selection

3D printers that use the extrusion process – that is, FDM technology – can work with a wide variety of filaments, such as PLA, ABS, PET-G, PVA, wood filaments, etc. ABS and PLA in particular are ideal for the production of architectural models.

If the print is to have a lot of detail, it may make sense to work with an SLA or DLP 3D printer.

Duration of 3D printing

Other cost factors undoubtedly include the duration of 3D printing. If a larger object or a detailed object is to be 3D printed, the 3D printer may have to work for several hours at a time. This of course affects filament and especially power consumption. Incidentally, if there is a power failure in the meantime or the filament runs out, more and more 3D printers are able to continue printing at the same point later.

Proportionate acquisition costs for the 3D printer

Just as with vehicles (keyword: mileage allowance in the tax return), the acquisition costs for the 3D printer should also be taken into account when calculating costs. After all, at least the purchase of a higher-priced device only pays for itself after a longer period of time and only if it is used regularly.

The prices for desktop 3D printers with functions for the architecture industry differ considerably. For conventional kit 3D printers, which are mainly used for private use and which could certainly also be suitable for the production of individual simple building models, start at around 150 euros. However, if you don't want to spend a lot of time tinkering with the setup and at the same time want to use a 3D printer that holds its value, you should invest in ready-to-use printers. Professional devices with a large installation space can also cost over 10,000 euros. The latter devices are used, for example, for the production of larger quantities.

3D scanner in architecture

In 3D printing in architecture and construction, as elsewhere, the main focus is on printing technology. But with 3D scanning, there is another interesting process that can also serve architects well. We would like to go into this briefly here.

3D scanners are used, for example, to capture interior spaces in homes and commercial buildings. The data thus generated is transferred to a computer and processed using appropriate CAD programs (for example, Autocad, Fusion 360, etc.). Such a process is used by some real estate agents to allow potential customers to virtually visit residential units or houses.

3D scanning can also be beneficial for historic buildings. If, for example, the construction drawings and other construction documents are only incomplete or not available at all, a 3D scanner can be used to create a detailed representation and determine at least some of the dimensions.

The best-known example of the use of 3D scanners in architecture is certainly the Sagrada Familia Cathedral in Barcelona, which is finally scheduled for completion more than 130 years after construction began. With the help of 3D scanners, models of individual areas of this sacred building were created, which now provide a basis for the further completion of the structure. Until the turn of the millennium, the individual models had been painstakingly handcrafted.

Further reading/sources:

  • https://minnature.com/
  • https://www.miamidesigndistrict.net/blog/entries/579/flotsam–jetsam-brings-one-of-the-worlds-largest-3d-printed-objects-to-miami/
  • https://i.materialise.com/blog/en/how-3d-printing-is-changing-architecture-learning-from-the-sagrada-familia-team-in-barcelona/