Application of Fractal Curves for 3D Concrete Printing of Porous Prefab Panels

3D Concrete Printing (3DCP) is an innovative automated construction method gaining recognition for its remarkable potential in design flexibility, material efficiency, and rapid construction. However, challenges such as local buckling, inadequate porosity, and limited geometric exploration hinder its broader application, especially in creating lightweight, insulative prefab panels. This study introduces a novel toolpath design for 3D printing using fractal geometry to achieve controlled porosity, enhancing cavity precision, reducing material consumption, and maintaining structural integrity. Key research questions include the influence of nozzle size on porous, drying rates on layer adhesion, and material efficiency in extended toolpath designs. The methodology combines generative design and computational modeling using Grasshopper, structural analysis with Karamba, and empirical validation through physical prototyping. The anticipated outcomes include lightweight prefab panels with enhanced porosity, superior structural performance, and effective cavity-driven insulation. By demonstrating the potential of fractal-inspired toolpaths, this research aims to address critical challenges in 3DCP and contribute to the evolution of sustainable and innovative construction technologies.