Enhancing polycarbonate Large-Scale Robotic 3D Printing through thermal control

Large-Scale Robotic 3D Printing (LSR3DP) enables the fabrication of customized architectural components; however, processing polycarbonate (PC) at large scale remains challenging due to its high glass transition temperature (Tg) and susceptibility to thermal shrinkage, which can lead to warping and cracking. This paper presents a temperature control strategy to enable stable LSR3DP of PC without relying on a fully enclosed heated environment. The approach is based on a custom hardware system that combines a modular heated printing platform, complementary infrared heaters, and a temperature-monitoring setup using thermal imaging and thermocouples. The system is designed as an add-on compatible with existing LSR3DP setups, aiming to maintain the deposited material at a temperature close to, but below, its Tg temperature throughout fabrication. The method is evaluated through a full-scale architectural case study involving the fabrication of six large PC panels. Compared to a reference print without thermal control, the proposed system significantly improves process stability, prevents cracking, and maintains controlled thermal conditions. Geometric assessment indicates deviations compatible with subsequent assembly by plastic welding, confirming the approach’s applicability to architectural-scale components.