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This research investigates using foam 3D-printing of cement-free mineral foams from recycled waste for monolithic, lightweight, and insulated wall construction. It aims to reduce the amount of material, labor, and costs required for bespoke building parts by leveraging moldless fabrication through large-scale robotic 3D-printing. Using porous materials with different densities provides insulation and strength where needed, which can reduce the operational energy necessary for heating buildings. Consisting of only one material with different densities facilitates the future reuse and recycling of building parts. Furthermore, the cement-free mineral foams by FenX have a lower carbon footprint than foamed concrete or plastic foams. The robotic 3D-printing system is developed at ETH Zürich in collaboration with FenX AG.
