Additive Manufactured Wall

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Interdisciplinary Centers, Units and Projects::Center for Undergraduate Research and Fellowships (CURF)::Fall Research Expo
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Architecture
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Design, Additive Manufacturing, Robotic Design
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2025-08-26
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Lew, Charlotte
Wu, Renhu (Franklin)
Stuart-Smith, Robert
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Abstract

This research explores a custom robotic approach to non-planar fused granulate fabrication (FGF) for the development of recyclable partition wall systems. Conventional wall assemblies often involve multi-material composites that are labor-intensive, costly, and generate substantial construction and demolition waste. By contrast, the proposed method employs recyclable PETG and polycarbonate thermoplastic pellets to fabricate mono-material panels that eliminate the need for additional framing while achieving zero-waste production. A computational design and manufacturing framework was developed to integrate variable extrusion rates, tool-paths, and layer geometries, enabling the production of self-supporting walls with unique structural and aesthetic qualities. Print layer testing with varying nozzle diameters, extrusion speeds, and heights provided insights into the relationship between fabrication parameters, material performance, and visual effects. Results demonstrate that the process achieves scalable wall systems with controlled translucency, geometric variation, and structural stability, offering a sustainable alternative to conventional partition construction.

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2025-09-15
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Penn Undergraduate Research Mentoring (PURM) program
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