Abstract
This article presents the development and validation of a design-to-fabrication framework aiming to improve the efficiency of fabricating reinforced concrete building components for housing projects in the Kingdom of Saudi Arabia by incorporating 3D concrete printing technology. In particular, the research presents an algorithmic framework to mass customise a typical Saudi Arabian free standing house by utilising parametric modelling, topology optimization (TO), finite element analysis (FEA), and robotic 3D printing tools and techniques. The framework was validated by the fabrication of optimised reinforced concrete columns and by testing their structural performance under the Saudi Building Code (SBC 304). The findings demonstrate the benefits and drawbacks of the proposed framework and compare it to current Saudi conventional construction approaches. The paper also addresses the need for mass customisation in the construction industry of the Kingdom of Saudi Arabia
•Design to fabrication of concrete building components.•Mass customisation of 3D-printing reinforced concrete frame structure.•Topology optimisation of 3D-printing reinforced concrete frame structure.•Validating structural performance of topology optimised column subjected to axial load.•Illustrating the efficiency of 3D printing optimised structural building components, mitigating labour and material waste.