Sustainability performance analysis of innovative small-scale 3D printed envelope sub-components

This paper, developed in the research projects REVERSING and R3NEW, investigates the sustainability performance of innovative small-scale 3D-printed envelope sub-components for the building sector. By analysing 13 case studies involving diverse materials and production techniques, the article aims to assess how Additive Manufacturing (AM) can support the construction sector's sustainability transition. Academic literature and websites of 3D printing research centres and companies were searched to collect data. Furthermore, data were analysed qualitatively against environmental, economic, and social sustainability parameters. Key findings reveal that small-scale 3D printing offers significant advantages in resource efficiency, design customisation, and process quality control, contributing to enhanced circularity and energy efficiency. However, challenges such as limited data availability, energy-intensive processes, and concerns over workers’ exposure to Volatile Organic Compounds remain unexplored. The study proposes a comprehensive system for mapping sustainability performance, focusing on the combined impact of multiple strategies on the overall sustainability of additive manufacturing processes and products on a building scale. Finally, the presented research provides a framework for professionals adopting 3D printing technologies in sustainable construction. It emphasises the need for an integrated evaluation of AM design, material selection, and process optimisation. Future research should focus on understanding process energy consumption control, life cycle assessment, and regulatory development to ensure safe and sustainable AM adoption in the construction industry.