Functionally Graded Additive ManufacturingAlireza Fazel, Rachael Henry, Wes McGee        2024

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In the biological world, material is rarely homogeneous and elemental. Natural materials like wood are complex composites composed of fibers and natural binders, while vertebrate bones feature continuous gradients of density; both configuration’s result in high stiffness to weight ratios. This research explores the emerging potential of functionally-graded, multi-material additive manufacturing (FGAM) to produce high performance, materially efficient building components. FGAM builds on the geometric freedom provided by typical 3D printing processes by adding the capability to locally tailor material composition continuously across a singular component. In the context of architecture and construction, this local tailoring could address daylight or air transmission, creating building components that more effectively manage solar heat gain and natural lighting, contributing to passive cooling and energy efficiency in buildings. Challenges such as thermal bridging can also be addressed with strategically placed insulating polymers. Simultaneously, the structural performance of components can be enhanced through materials with tunable density and stiffness. FGAM also allows multiple building components to be consolidated, eliminating interfaces and mechanical connections which are prone to fail or leak. This overall goal of this approach is to reduce material usage and improve the overall quality and performance of the printed elements, leading to lower energy consumption and CO2 emissions.

Additional credits:
Research Assistant: Jutang Gao