A Cradle-to-Grave Lifecycle Perspective on 3D-Printed Facades: Assessing Environmental Potential and Uncertainties

Abstract

Facades significantly impact a building's environmental footprint. Efforts so far have primarily focused on reducing operational emissions by energy-efficient designs. However, embodied emissions from materials and construction are also crucial, potentially comprising up to 30% of a building's total embodied emissions depending on its type and structure. Novel technologies like 3D-printed Facades (3DPF) promise emission reductions through material efficiency, multifunctionality, and the use of recycled materials such as plastics. Yet, few studies fully assess their life-cycle impact, highlighting the need for further research. This study extends beyond cradle-to-gate assessments of digitally fabricated components by adopting a cradle-to-grave approach that covers all lifecycle stages of a 3DPF case study. It addresses uncertainties in the production and lifecycle of 3DPF, formulating scenarios for 3D printing material production, end-of-life options, and service life. A comparative Life-cycle Assessment (LCA) evaluates how 3DPF performs against existing facade technologies, including translucent glass, polycarbonate facades, and shaded glazing units. Key factors and lifecycle stages for 3DPF are identified, stressing the environmental benefits of multifunctional integration and material upcycling. Recycled 3DPF offers substantial environmental gains, while virgin polymer 3DPF has a larger footprint, with nearly three times the impact of recycled versions. Different polymer materials are also considered and compared. For recycled 3DPF, optimizing the printing process and energy sources could further reduce the environmental impact. This study contributes to the search for sustainable facade materials and highlights environmental hotspots in the lifecycle of 3DPF, which are crucial to enhancing the sustainability of this novel technology. However, uncertainties around service life and end-of-life scenarios for 3DPF remain significant for LCA outcomes, underscoring the need for further data collection and experimental testing to fully realize the environmental potential of this promising technology.