Preliminary Optimization of Steady-State and Dynamic Thermal Performance of 3D Printed Foamed Concrete

The integration of Foamed Concrete (FC) into 3D Concrete Printing (3DCP) processes facilitates the design of energy-efficient building envelopes. However, strategies for optimizing material porosity and printing topology to balance winter and summer performance remain underexplored. This study presents a 2D numerical thermal analysis of an innovative 3D-printed building envelope block characterized by sinusoidal internal partitions. Through a parametric variation in porosity (ranging from 10% to 50%) and internal geometry (amplitude and period of the partitions), 45 distinct configurations were simulated. Performance was evaluated by calculating the steady-state thermal transmittance (U) and the periodic thermal transmittance (Yie) under dynamic climatic conditions. The results demonstrate that porosity is the governing parameter; increasing porosity from 10% to 50% reduces U by 31% and, contrary to traditional assumptions for massive structures, also improves Yie by 12.3%. These outcomes are physically driven by the drastic reduction in thermal conductivity, which overcompensates for the loss of thermal mass, leading to a net reduction in overall thermal diffusivity. While internal topology plays a secondary role, its optimization allows for fine-tuning dynamic damping without compromising insulation. The study confirms that 3D printing with foamed concrete enables the overcoming of the traditional trade-off between insulation and thermal inertia. High-porosity configurations (50%) with optimized internal topology emerge as the most effective solution, simultaneously guaranteeing beneficial steady-state and dynamic thermal performance for sustainable buildings.