Greenhouse Gases Emission Reduction Trough Topology Optimization and 3D Printing

The construction sector, accounting for 8% of global CO2 emissions and utilizing 40% of extracted natural resources, faces a crucial challenge in reducing greenhouse gas emissions (GHG) and adopting sustainable waste management practices [1]. Alarmingly, the sector ranks near the bottom in terms of digitization, according to the MGI Industry Index. To enhance competitiveness and efficiency in resource management, automation is needed in the construction sector. To address these challenges, we propose a digital design methodology that integrates topology optimization (TO) gradient-based approaches with additive manufacturing (AM) for cementitious structure design. This approach leverages the advantages of complex and non-intuitive optimized forms. It involves creating a three-dimensional mathematical model, discretizing it using finite element methods (FEM), and applying TO to achieve minimum compliance design within volume and manufacturing constraints. The finalized design is then constructed using 3D Concrete Printing (3DCP) within an integrated CAE-CAD-CAM system. By integrating these digitally optimized TO design methods with AM and low-carbon footprint cementitious materials, significant reductions in GHG emissions can be achieved, enhancing productivity in the civil construction industry.