@article{article_1792446, title={Optimization of Internal Patterns in 3D-Printed Walls to Control Heat Transfer and Embodied Impact}, journal={Black Sea Journal of Engineering and Science}, volume={9}, pages={1–2}, year={2025}, DOI={10.34248/bsengineering.1792446}, author={Kul, Anıl}, keywords={Eklemeli İmalat, Robotik 3D Beton Yazdırma, Termal Performans, Yaşam Döngüsü Değerlendirmesi, Atık Yönetimi}, abstract={This study develops and evaluates a 3D-printable, waste-based alkali-activated mortar designed for improved thermal insulation in building applications. Brick masonry waste is utilized as both binder and aggregate to address sustainability challenges associated with ordinary Portland cement and scarce industrial by-products. A series of mix formulations with increasing recycled brick waste content (50–80% of total solids by weight) were produced and tested for fresh properties, mechanical strength, and thermal conductivity. The optimal mix (BA0.7) balanced extrudability, buildability, and strength with a low thermal conductivity, and was successfully used in 3D printing experiments. Numerical simulations were then conducted on five wall geometries with varying internal void configurations using the measured material properties. The finite element thermal analysis was first validated against literature data, showing close agreement in thermal transmittance (U-value). Results demonstrate that increasing the wall’s void ratio significantly reduces U-values, indicating better insulation, yet the geometry and distribution of load-transfer “contact points” between wall layers strongly influence heat flow. The best-performing 3D-printed wall design achieved a U-value of ~4.1 W/m²K, a 75% reduction compared to a solid wall of the same thickness. A cradle-to-gate life-cycle assessment (LCA) revealed that, after optimization of the internal pattern, the 3D-printed wall achieved an approximately 70–80% reduction in embodied impacts relative to the solid baseline. These findings highlight the potential of combining recycled-waste geopolymer materials with optimized 3D-printed wall designs to create lightweight, thermally efficient building envelopes. The novel material and wall configurations proposed can reduce building energy consumption and carbon footprint, supporting a transition toward sustainable construction. Future research should explore durability, multi-functional optimization (e.g. acoustic and structural performance), and the integration of passive insulation strategies to further enhance these 3D-printed systems.}, number={1}, publisher={Karyay Karadeniz Yayımcılık Ve Organizasyon Ticaret Limited Şirketi}