The article explores innovative methods for creating high-insulation walls, essential for the future of energy-efficient and sustainable construction. It focuses on advanced 3D-printing technologies that allow for the construction of walls with superior insulation materials, optimizing thermal properties and significantly reducing energy for heating and cooling. The integration of thermal insulation within wall structures and innovations in building materials like lightweight composites, aerogels, and nanotechnology-based insulations are highlighted. It discusses the environmental, economic, and technical benefits of these innovations and the challenges to fully leverage 3D printing in construction. Future development directions emphasize materials that enhance thermal efficiency, sustainability, and functionality, promising a new era of sustainable and innovative construction practices.

This study examines the pore structure and distribution in 3D printed and cast foamed concrete using protein-based and synthetic foaming agents alongside various stabilizing additives. In 3D printed samples, pores are irregular and flattened due to mechanical forces during printing, whereas cast samples display uniform, spherical pores from homogeneous foam distribution. Samples containing the CA stabilizer show higher apparent densities (up to 2.05 g/cm³ for printed samples), correlating with lower water absorption. Protein-based foaming agents (PS) produce smaller, more evenly distributed pores, while synthetic agents (AS) result in larger, less uniform pores. Stabilizers significantly influence pore characteristics: commercial stabilizers yield smaller, more uniform pores, while recycled industrial oil (UO) leads to larger, more variable pores. Protein-based agents improve structural stability and reduce water absorption through uniform pore distributions, while synthetic agents lower density and increase water absorption. The highest sorption values were observed in samples with AS without stabilizer (1.7 kg/m²h¹/²) and AS and UO (1.6 kg/m²h¹/²) in a vertical orientation, with the horizontal orientation of sample AS and UO achieving a peak value of 2.0 kg/m²h¹/². Moreover, stabilization using UO resulted in higher sorption coefficients than stabilization with CA. High porosity in M1 resulted in low strength (0.2 MPa bending, 0.1 MPa perpendicular compression), while M5 showed superior performance (11.5 MPa perpendicular compression). PS-foamed samples (M4, M6) with uniform pores had the highest strengths, with M6 achieving 3.8 MPa bending and 10.3 MPa perpendicular compression. Perpendicular compression (M5: 11.5 MPa) was up to three times stronger than parallel compression due to weak interlayer bonds in 3D printing.

In the face of accelerating urbanization and the growing demand for environmentally responsible materials and designs, this study presents the development and implementation of a modular parklet demonstrator fabricated using dual-material 3D printing. The structure integrates polylactic acid (PLA) and wood-filled PLA (wood/PLA), combining the mechanical robustness of pure PLA in the core with the tactile and aesthetic appeal of wood-based biocomposite on the surface. The newly developed dual-nozzle 3D printing approach enabled precise spatial control over material distribution, optimizing both structural integrity and sustainability. A comprehensive evaluation was conducted for developed filaments and printed materials, including optical microscopy, coupled thermogravimetry analysis and Fourier Transform Infrared Spectroscopy (TG/FTIR), differential scanning calorimetry (DSC), and chemical and mechanical resistance testing. Results revealed distinct thermal behaviors and degradation pathways between filaments and printed parts composed of PLA and PLA/wood. The biocomposite exhibited slightly increased sensitivity to aggressive chemical environments and mechanical wear, dual-material prints maintained high thermal stability and interlayer adhesion. The 3D-printed demonstrator bench and stools were successfully deployed in public spaces as a functional urban intervention. This work demonstrates the feasibility and advantages of using biocomposite materials and dual-head 3D printing for the rapid, local, and sustainable fabrication of small-scale urban infrastructure.

Concrete 3D printing (3DCP) combines materials science with material processing technologies to enable automated, additive construction. This review summarizes findings from the literature and industrial practice on 3DCP mortar formulation with emphasis on the material processing chain. The workflow is examined from raw material storage through handling, mixing, and deposition. The roles of binders, aggregates, dispersed reinforcement, and chemical admixtures are discussed in relation to rheological behavior, buildability, and early-age mechanical performance. The analysis covers storage, dosing, and mixing strategies with respect to mix consistency and overall process reliability, while mortar pumping and extrusion are addressed alongside nozzle-injected additives and automation. Finally, limitations and scalability challenges are outlined with research directions such as continuous mixing, in-line monitoring, and adaptive mix formulation for on-site applications.