A Holistic Modular Solution for Energy and Seismic Renovation of Buildings Based on 3D-Printed Thermoplastic Materials

This paper introduces a novel modular retrofitting solution to enhance the energy efficiency and seismic resilience of building façades, particularly within the Portuguese context. In the context of Europe’s “Renovation Wave” strategy, and as a product of the nationally funded ZeroSkin+ project, the proposed renovation solution addresses the urgent need for sustainable building renovations to help mitigate climate change and meet European climate neutrality goals by 2050. Unlike traditional methods that often rely on non-eco-friendly materials without integrating seismic and thermal performances, the renovation solution leverages fused deposition modelling (FDM) 3D printing technology to introduce a dual-layered panel system. This system features a durable, UV-resistant PET-G thermoplastic outer layer and a cork interior to ensure additional thermal insulation. The integrated renovation solution shows a 42% improvement in seismic reinforcement’s out-of-plane capacity and achieves U-values as low as 0.30 W/m2·K, exceeding Portugal’s thermal efficiency standards (0.35 to 0.50 W/m2·K). The proposed renovation solution also embraces circular economy principles, emphasising waste reduction and recyclability.