Evaluating the Performance of Fixed 3D-Printed and Dynamic Fabric Modules in a Second-Skin Façade System: A Residential Case Study in Southern Italy at Building and District Scales

The building sector accounts for 30% of worldwide final energy usage and 26% of global energy-linked emissions. In construction, innovative materials and systems can offer flexible, lightweight, energy-efficient solutions to achieve more efficient buildings. This study addresses the energy analysis and environmental impacts of retrofitting residential buildings in Monterusciello, Italy, using an innovative second-skin façade system design that incorporates 3D-printed and fabric modules. The purpose is to enhance energy efficiency and reduce the environmental impact of residential buildings originally constructed with prefabricated elements that have degraded over time. This research employed TRNSYS modelling to simulate energy consumption and environmental impacts at the single-building and whole-district levels, analysing the system’s effectiveness in reducing cooling and heating demands and using different materials for optimal performance. The results show that retrofitting with the second-skin façade system significantly reduces cooling energy demand by 30.2% and thermal energy demand by 3.84%, reaching a primary energy saving of 16.4% and 285 tons of CO2 emissions reduction for the whole district. The results highlight the potential of second-skin façade systems in improving energy efficiency and environmental sustainability, suggesting future research directions in material innovation and adaptive system development for district-wide applications.