Three-Dimensionally Printed Gypsum Located Within Micro-Encapsulated Phase Change Material: Thermal Conductivity Benefits of Selective Activation Technique

The widespread occurrence of encapsulated phase change materials (PCMs) within a mineral matrix has been demonstrated to improve the thermo-physical properties of final products. The upscaling of such materials has not yet been achieved, as traditional onsite mixing and casting processes could damage the capsule, leading to a leakage of the active content and then a deterioration of the final element. The aim of this paper is to evaluate the influence of selectively depositing a layer of PCM on plaster, through a powder bed 3D printing process, on its density and thermal conductivity. A home-made selective-binding 3D printer has been used to assess samples of composites of calcium sulfate and encapsulated PCM. Thermal conductivity and Scanning Electron Microscope measurements were carried out on pure calcium sulfate as well as on a mix design containing a 5% mass ratio of PCM. The SEM measurements highlight that the PCM shells are undamaged by the selective-binding 3D printing process compared to the traditional mixing and casting process. Also, the 3D-printed composite material demonstrates a thermal conductivity reduction of 39%, which is linked to the 17% decrease in density. This applicative study validates the idea of designing functionally composite construction materials with phase change materials inserted as a thin layer between printed plaster layers and also demonstrates the great potential of this innovative selective-binding 3D printing technique.