The Impact of 3D Printing Technology on the Improvement of External Wall Thermal Efficiency—An Experimental Study

Three-dimensional printing technology continues to evolve, enabling new applications in manufacturing. Extensive research in the field of biomimetics underscores the significant impact of the internal geometry of building envelopes on their thermal performance. Although 3D printing holds great promise for improving thermal efficiency in construction, its full potential has yet to be realized, and the thermal performance of printed building components remains unexplored. The aim of this paper is to experimentally examine the thermal insulation characteristics of prototype cellular materials created using 3D additive manufacturing technologies (SLS and DLP). This study concentrates on exploring advanced thermal insulation solutions that could enhance the energy efficiency of buildings, cooling systems, appliances, or equipment. To this end, virtual models of sandwich composites with an open-cell foam core modeled after a Kelvin cell were created. They were characterized by a constant porosity of 0.95 and a pore diameter of the inner core of the composites of 6 mm. The independent variables included the different material from which the composites were made, the non-uniform number of layers in the composite (one, two, three, and five layers) and the total thickness of the composite (20, 40, 60, 80, and 100 mm). The impact of three independent parameters defining the prototype composite on its thermal insulation properties was assessed, including the heat flux (q) and the heat transfer coefficient (U). According to the experimental tests, a five-layer composite with a thickness of 100 mm made of soybean oil-based resin obtained the lowest coefficient with a value of U = 0.147 W/m2·K.