Porous Loops is a lightweight composite facade panel that was developed during a 12 week long master thesis project as part of a larger research endeavour investigating 3D printing (3DP) of mineral foams. This material group is used in construction because of its insulating and lightweight properties. For the first time a building scale application using 3DP of mineral foam is presented.
The innovative mineral foam developed by FenX AG is derived from abundant industrial waste, non-flammable and fully recyclable. In this research project the printed foam elements were sintered in a furnace to achieve their full mechanical strength. After sintering, all foam elements were assembled within a metal frame with reinforcement pins and cast out using fibre-reinforced ultra high performance concrete (UHPC). The resulting composite facade panel shows the potential of using 3DP of mineral foams for bespoke lightweight architectural elements.