Workflow and Lab-Scale Demonstrator of an on-substrate 3D-Printed Window Frame
Additive Manufacturing offers significant potential in construction by directly converting digital designs into physical objects. However, this potential is constrained by the separated fabrication approach–components are printed away from their final location and later installed. Inherent to most AM processes, it disrupts automation and adds complexity to the construction process. This study demonstrates a laboratory on-substrate workflow that prints directly onto the receiving substructure. A comprehensive workflow was developed, integrating digital design, slicing, and robotic on-substrate Additive Manufacturing to address challenges such as printing directly onto pre-existing structures, handling multiple orientations, and managing complex geometries. Experimental validation was conducted using a robotic Additive Manufacturing setup, demonstrating the fabrication of a fixed glass window frame prototype with varied material properties during printing. The window frame was 3D-printed in 4 hours, 10 minutes, and 34 seconds. Findings suggest that on-substrate Additive Manufacturing with thermoset polymers is a viable approach, offering potential for streamlined construction and enhanced customisation, laying the groundwork for scalable, automated façade construction.