Integration of a 3D-Printed Façade Unit in a Curtain Wall System: Prototyping and Assessment

Plastic materials, known for their lightweight, formability, transparency, and durability, are the state of the art for building façade applications. Recent advances in Large-Scale Robotic 3D Printing (LSR3DP) have enabled the production of bespoke, translucent façade components. While research has largely focused on individual panel properties, there is a gap in developing a comprehensive strategy for integrating these components into a complete façade system. This paper explores the potential of combining custom 3D-printed façade elements with standard curtain wall connections. Quantitative analysis involves constructing and testing a 1 m x 1 m LSR3DP façade assembly for air and water tightness, benchmarking its performance against a conventional curtain wall. Qualitatively, the approach is evaluated through a mock-up, highlighting the architectural possibilities of blending standard and non-standard façade elements. The findings demonstrate that this hybrid system is both technically viable and opens new design possibilities for architects and façade engineers.