Three-dimensional printing, or additive manufacturing, is one of the modern techniques emerging in the construction industry. Three-Dimensional Printed Concrete (3DPC) technology is currently evolving with high demand amongst researchers, and the integration of modular building systems with this technology would provide a sustainable solution to modern construction challenges. This work investigates and develops energy-efficient 3D-printable walls that can be implemented worldwide through energy efficiency and sustainability criteria. Numerical research and experimental investigations, bench tests with software packages, and high-precision modern equipment have been used to investigate the thermal performance of 3DPC envelopes with different types of configurations, arrangements of materials, and types of insulation. The research findings showed that an innovative energy-efficient ventilated 3DPC envelope with a low thermal conductivity coefficient was developed following the climatic zone. The annual costs of heat energy consumed for heating and carbon footprint were determined in the software package Revit Insight to assess the energy efficiency of the 3D-printed building. The thermal properties of the main wall body of the tested 3D-printed walls were calculated with on-site monitoring data. The infrared thermography technique detected heterogeneous and non-uniform temperature distributions on the exterior wall surface of the 3DPC tested envelopes.

Life cycle assessments in the construction industry reveal that 70–80% of all CO₂ emissions occur precisely at the stage of material production (stages A1–A3 of the life cycle). Therefore, not only does the strength and thermal properties of the material selected for construction have major importance, but also the environmental impact of the material and the amount of energy spent to extract, manufacture and transport the materials. The paper presents the thermal calculations for envelope structures, assessing their environmental impact with respect to three parameters: carbon dioxide emissions, total energy consumption and amount of waste generated during material production. The research method used was an analysis of documents from real manufacturers and calculations of the main environmental parameters. Our investigation has led us to conclude that the largest amount of carbon dioxide emissions is produced by structures containing reinforced concrete, since the weight fraction of concrete is significantly greater than that of all other compared materials. The largest amount of non-renewable energy is consumed by structures containing clay bricks and reinforced concrete, since they consist of natural sources. The largest amount of waste is generated by structures containing expanded polystyrene and reinforced concrete consisting of cement, whose production in turn generates a large amount of waste.

The main development direction of energy efficiency technologies in construction is the creation of various materials with complex structures and unique strength, thermal properties, and other properties. The aerogel is a material with high porosity and excellent thermal insulation properties. This paper provides state-of-the-art aerogel applications for the additive manufacturing of energy-efficient buildings. This work provides the experimental and numerical assessment results of the thermal conductivity of aerogel-enhanced blanket, the experimental assessment results of thermal performance of aerogel-enhanced building structure, the experimental assessment results of the aerogel application as a mixture powder component of the concrete mixture to printing buildings, and the experimental assessment results of the aerogel application as a parget powder component. Experimental results show the effect of aerogel powder component application: thermal conductivity decreased by 25%.