Comparative analysis of 3D printing technology and conventional construction methods in construction practices: a case study based on biomimetic design and AI-generated form-finding
Abstract
Recently, 3D printing has emerged as a groundbreaking fabrication technology, enabling the precise fabrication of complex structures directly from digital models. Despite its potential, integrating 3D printing into architectural design and construction practices remains a significant challenge, establishing a digital construction culture worldwide. Accordingly, this paper aims to evaluate the feasibility of integrating 3D printing into practical construction applications through a comparative analysis of the production sequence of a large-scale structure fabricated using 3D printing and the same structure constructed using conventional construction methods. The study adopts an integrated digital workflow beginning with biomimicry as a form-finding approach, focusing on five common organisms in Port Said, Egypt. Then, the AI platform Midjourney is used as a form-finding tool to transform bio-inspired patterns into initial design proposals. Subsequently, these designs are developed into parametric models using Rhino/Grasshopper, followed by structural integrity and environmental performance simulations to identify the optimal design. Finally, two construction scenarios are simulated for the selected design: Fused Deposition Modeling (FDM) 3D printing with Acrylonitrile Butadiene Styrene (ABS) and conventional construction methods with reinforced concrete. These methods are compared using a unified set of criteria, including design and functionality, time and cost considerations, sustainability and environmental impact, and quality control. The findings indicate that 3D printing, under controlled fabrication conditions, enables the fabrication of complex, large-scale, lightweight, free-form geometries with high geometric resolution compared to conventional construction methods. It also significantly reduces production time, material waste, and labor, ensures efficient assembly and disassembly, while achieving high-quality surface finishes.