Developing a design framework for the 3D printing production of concrete building components: A case study on column optimisation for efficient housing solutions for Saudi Arabia

This paper is examining the development of a design and fabrication framework aiming to increase the efficiency of the construction of concrete building components by introducing 3D concrete printing in the context of Saudi Arabia. In particular, we will present an algorithmic process focusing on the design and fabrication of a typical, mass customised, single-family house, which incorporates parametric modelling, topology optimisation, finite element (FE) analysis and robotic 3D printing techniques. We will test and verify our framework by designing and fabricating a loadbearing concrete column with structural and material properties defined by the Saudi Building Code of Construction. Our findings are highlighting the advantages and challenges of the proposed file-to-factory framework in comparison to the conventional construction methods currently applied in Saudi Arabia, or other similar sociopolitical contexts. By comparing the material usage in both conventional and optimised columns, the results have shown that material consumption has been reduced by 25%, the required labour in the construction site has been mitigated by 28 and the duration time has been reduced by 80% without the need for formwork.