The building sector is a big contributor to environmental problems. It is responsible for the extraction of 24% of earths raw materials, it generates 40% of total waste and 40% of the total energy use comes from the built environment. The building industry focusses on production rather than lifespan, leading to materials not being separable. This means a shift towards a circular economy is necessary.
This thesis aims for improving the circular potential of additive manufactured mono-material façade elements through the design of a demountable connector. This was achieved through both circular analysis of an additive manufactured façade element, Spong3D, and research through design of a demountable connector.
Through literature it was found that additive manufacturing has the potential to produce circular building products. Through reducing material use with shape optimization, and the ability to make mono-material elements. And the ability to make complex shapes, which allow for demountable connectors and thus reuse.
The Spong3D panel was analysed on its circular potential and compared to the circular building product Hempcrete. It was found that the Spong3D element was not designed with circularity in mind. However, the current design can be improved upon to improve its circular potential. It is already mono-material, which allows for reusing and recycling. Further improvements include using recycled materials, and optimizing the shape, thus reducing the raw materials used. Lastly, a demountable connector adds reusing potential.
This connector was designed in the prototyping stage of this thesis. Multiple designs were made and evaluated in a decision model consisting of circularity requirements for the entire lifespan of a product. The final design, C-cure, consists of the Spong3D panel and a locking element, two sides of the panel connect together, and the locking element rotates into a recess, locking the panels into place. The design fulfilled all circular requirements.
The C-cure connector uses little energy to produce. It allows the Spong3D to assemble and disassemble and is a reliable connector in use.