Modular three-dimensional printed clay structure for water detention, diversion, and containment and method of making

Abstract

A three-dimensional (3D) printed structure includes a body having a plurality of layers of a printed material, the printed material traversing an interior of the body, where the body is printed at architectural scale for use as a building component. The body includes geometric features configured to collect water, detain water, and direct the release of water.

Description

Atty. Docket No. 10110-24014A-W0MODULAR THREE-DIMENSIONAL PRINTED CLAY STRUCTURE FOR WATER DETENTION, DIVERSION, AND CONTAINMENT AND METHOD OF MAKING THE SAME

[0001] This application claims the benefit of U.S. provisional application entitled “Modular Three-Dimensional Printed Clay Structure For Water Retention, Diversion, And Containment And Method Of Making Same,” filed August 9, 2024, and assigned Serial No. 63 / 681 ,370, the entire disclosure of which is hereby expressly incorporated by reference.BACKGROUND OF THE DISCLOSUREField of the Disclosure

[0002] The disclosure generally relates to the general use of three- dimensional (3D) printing (3DP) for modular clay building envelope components (roof, facade, and integration with other building infrastructural and drainage systems) to retain, detain, divert, and hold water.Brief Description of Related Technology

[0003] Historically, different regions in the U.S. extract clay locally for manufacturing of building components and structures, such as roof tiles, drains, facades, rain-screen systems, and infrastructural elements like ollas for passive irrigation. These building elements are manufactured industrially with different processes such as pressing or stamping, extrusion (using a die), slip casting, or handbuilding. The material structure of clay in relation to water is determined by absorption level which depends on the clay body’s material composition and, after firing, how the pore size and shape interacts with water in diverse ways. Fired elements can be fully recycled (without glazing) by grinding up into various particle sizes and reincorporated as grog to control clay body’s shrinkage and overall strength for durability when fired. Typically, for building elements, clay components are glazed and fired, reaching vitrification for durability. Clay as a material is typically used for the following properties and applications: thermal properties for heat retention or evaporative cooling; sound absorption; water absorption orAtty. Docket No. 10110-24014A-W0 resistance (especially after being glazed); filtering of contaminates (aqueous); and fireproofing.

[0004] Ceramics are commonly used in architectural applications and are typically manufactured in a variety of ways (slip cast, extruded, stamped) to perform as rain-screens, intended to repel water away from the building. Clay three-dimensional (3D) printing (3DP) is widely employed for vessel-size fabrication of vases, pots, and cups. 3DP henceforth refers only to clay extrusion processes using commercially available printing systems or customized robotic arm extrusion. 3DP building components for architectural uses have focused on aesthetic applications of customizable geometry and glazing for decorative purposes. There are also small-scale tiling designs that are 3D printed for building envelopes or rain screens to be architecturally deployed. The state-of-the-art 3DP technology leverages geometric complexity for surface textures possible with 3DP for decorative purposes and visual openings, e.g. for architectural screens. Contemporary integration of biophilic designs incorporate mosses, algae, and bacteria for diverse functions such as air filtering, aesthetic effects, cooling, water retention properties with plant growth, and self-healing properties with bacterial secretion of calcium carbonate.SUMMARY OF THE DISCLOSURE

[0005] In accordance with one aspect of the disclosure, a three-dimensional (3D) printed structure includes a body including a plurality of layers of a printed material. The printed material traverses an interior of the body. The body is printed at architectural scale for use as a building component. The body includes geometric features configured to collect water, detain water, and direct the release of water.

[0006] In accordance with another aspect of the disclosure, a method of manufacturing an architectural-scale ceramic building component includes printing, by a three-dimensional (3D) printer based on printing parameters, a plurality of layers of clay to form a body, wherein the plurality of layers of clay have a geometry traversing an interior of the body, the geometry being configured to collect water, detain water, and control the release of water. The method also includes firing the plurality of layers of clay to form the ceramic building component.Atty. Docket No. 10110-24014A-W0

[0007] In connection with any one of the aforementioned aspects, the structures and methods described herein may alternatively or additionally include any combination of one or more of the following aspects or features. The printed material comprises clay. The geometric features include body surface textures, infill patterns of the plurality of layers of printed material, channeling within the body, or combinations thereof. The body surface textures include portions of a set of layers of the plurality of layers protruding outward from a surface of the body relative to other layers of the plurality of layers. The infill patterns of the plurality of layers of printed material create negative spaces within the body. The negative spaces are interconnected. The negative spaces are configured to maximize surface area and detain water, such that the structure is operable to perform evaporative cooling. The channeling within the body includes a tube-like component traversing an interior of the body, where at least one end of the tubelike component comprises an opening in a sidewall of the body. The geometric features prevent slumping during printing of the printed material. The building component includes a fagade tile, a roof tile, or a masonry unit. The body is configured to interconnect in a modular fashion with other bodies having a same or similar design. The material is selected based on climate conditions where the body is to be used as the building component. The material is configured to interface with biological elements. The geometry includes surface textures, infill geometries of the ceramic building component, or combinations thereof. The method of manufacturing an architectural-scale ceramic building component further includes controlling the surface textures and infill geometries based on the printing parameters. The infill geometries include interconnected negative spaces within the ceramic building component. The geometry of the ceramic building component includes one or more tubes spanning an interior of the ceramic building component. The geometry of the ceramic building component prevents slumping during the printing of the ceramic building component. The method of manufacturing an architectural-scale ceramic building component further includes selecting the printing parameters based on predetermined climate conditions. The method of manufacturing an architectural-scale ceramic building component further includes aggregating a plurality of ceramic building components to form facades, roof tiles, or masonry units.Atty. Docket No. 10110-24014A-W0BRIEF DESCRIPTION OF THE DRAWING FIGURES

[0008] For a more complete understanding of the disclosure, reference should be made to the following detailed description and accompanying drawing figures, in which like reference numerals identify like elements in the figures.

[0009] Figure 1 shows a diagram depicting design parameters and performance metrics of a hygroscopic envelope on a micro-scale, meso-scale, and macro-scale in accordance with one example.

[0010] Figure 2 illustrates 3D printed surface textures in accordance with several examples.

[0011] Figure 3 illustrates 3D printed infill geometries in accordance with several examples.

[0012] Figure 4 illustrates bead control for surface textures and infill geometries in accordance with several examples.

[0013] Figure 5 illustrates an infill geometry design showing printed clay as positive material and negative space where water can occupy in accordance with one example.

[0014] Figure 6 illustrates sectional views showing negative spaces within infill geometries in accordance with several examples.

[0015] Figure 7 illustrates surface textures, geometry of a print path, and a digital model of an infill geometry design in accordance with one example.

[0016] Figure 8 illustrates different views of an infill geometry with scoop texture design in accordance with one example.

[0017] Figure 9 illustrates an example of a 3D printed ceramic component having intersecting tubes in accordance with several examples.

[0018] Figure 10 shows a diagram depicting climate specificity in relation to the three scales shown in Figure 1 .

[0019] Figure 11 illustrates an infill geometry design with print parameters and water test results in accordance with one example.

[0020] Figure 12 illustrates a method of manufacturing an architectural-scale ceramic building component in accordance with one example of the present disclosure.Atty. Docket No. 10110-24014A-W0

[0021] Figure 13 illustrates how conventional rain screens function to repel water away from the building facade in contrast to the intended performance of a hygroscopic envelope system in accordance with one example.

[0022] Figure 14 illustrates how water interacts with material at the micro scale, with printed geometries at the meso scale, and channeling of water at the macro scale.

[0023] Figure 15 illustrates prototype assemblies, in accordance with two examples.

[0024] Figure 16 illustrates printed geometries and designs to account for mounting details, integration of pipes, and for protecting the ceramic component using gaskets in accordance with several examples.

[0025] Figure 17 illustrates landscape / infrastructural scale components printed with different clay bodies and geometries in accordance with two examples.

[0026] Figure 18 illustrates samples of different densities of printed material to maximize surface area and through ventilation for evaporative cooling purposes in accordance with several examples.

[0027] Figure 19 illustrates additional examples of print paths, surface geometries, and digital models in accordance with two examples.

[0028] Figure 20, illustrates an infill design that can perform as an evaporative cooling device in accordance with one example.

[0029] Figure 21 illustrates infill designs that can perform as landscape elements for retaining and / or detaining stormwater in accordance with two examples.

[0030] While the disclosed structures and methods are susceptible of embodiments in various forms, there are illustrated in the drawings (and will hereafter be described) specific embodiments of the invention, with the understanding that the disclosure is intended to be illustrative, and is not intended to limit the invention to the specific embodiments described and illustrated herein.Atty. Docket No. 10110-24014A-W0DETAILED DESCRIPTION OF THE DISCLOSURE

[0031] As cities expand, there are less softscapes that can effectively hold excess water during flash storms — especially as more severe and frequent storms become the norm due to climate change. Rebuilding after flooding is costly and unsustainable, with demands on construction materials and labor, and contaminated materials contribute to landfill waste. Mitigation against flooding is not only an environmental and infrastructural concern, but is tied to economic and social equity. Solutions for climate adaptation for our built infrastructure not only need to be environmentally sustainable, but must also be understood in the context of broader economic and social factors.

[0032] Given that buildings occupy a significant footprint and surface area of urban areas, their exterior envelopes and immediately adjacent landscapes present a unique opportunity to contribute to stormwater management by helping to literally retain and / or detain water, thereby slowing runoff to sewer systems that were not originally designed for such extreme conditions. The disclosed system is designed to work at normal to extreme rainfall levels. As used herein, the terms “retain” and “retention” refers to holding or storing water somewhat permanently, whereas the terms “detain” or “detention” refer to a temporary holding or storage of water.

[0033] Modular ceramic systems are often used for channeling and shedding water from buildings, e.g. roof tiles, gutters, shingles, drains, and rain screens. Ceramic vessels have historically been used to hold water, but they also have the ability to release water through the material (such as olla pots used for irrigation). This unique material property, when considered as facade elements (i.e., architectural ceramics), may enable the capture and detention and / or retention of water, literally to sponge up the water and slowly release it later. Ceramic materials (e.g., fired clay) should also be considered for construction due to their reduced embodied carbon compared to other building materials such as concrete, steel, and glass. Clay can be locally sourced, similar to other earth-based construction materials. Ceramics also have thermal and acoustic insulation properties that can be leveraged for climate controls. Ceramics are fire retardant, and advanced processes and blending of the material have enabled incorporation of waste streams and geopolymerisation that help with strength, durability, and CO2 reduction. Ceramic fabrication is zero waste, as 100% of ceramics can be recycled as ‘grog,’ a component added to clay to temper shrinkage and cracking duringAtty. Docket No. 10110-24014A-W0 drying and firing. Unfired clay can also be reprocessed fully for reuse. Further, due to clay’s molecular structure, it has adsorptive properties that are used to filter pollutants such as heavy metal ions from water.

[0034] Additive Manufacturing, commonly known as 3D printing (3DP), of ceramic components can incorporate variability and customization to open new opportunities for optimizing water detention and / or retention in architectural and construction projects. The present disclosure aims to leverage the automation and customization possibilities with 3DP to design ceramic units capable of being stacked or hung in a modular fashion. Clay printing has thus far been overwhelmingly focused on the object scale of vessels (e.g., vases, pots, and cups) with complex forms and intricate patterning. The present disclosure focuses on clay printing for use in the architectural or building scale (i.e., printing clay components large enough to be used for diverse architectural applications). The advantages of 3DP clay include automation in manufacturing, high degrees of geometric control without custom molding, and a uniform extruded thickness to allow for even drying and, more importantly, even shrinkage during firing.Typically, for printed clay to keep from slumping, connections, “webbings,” “infills,” or other internal structures are made between two walls to stiffen the vertical surface, allowing for larger prints. The present disclosure allows for the understanding of structural stiffness in relation to geometry (during printing and as finished modules) and optimizing material efficiencies. In this way, the present disclosure allows for more than simple absorption of water due to the use of ceramic and allows for intentional channeling and directing of water by being able to optimize the design of the printed ceramic units, specifically the infill patterns or internal structure of the ceramic units.

[0035] The present disclosure relates to how 3DP ceramic structures, such as facades, can enable climate adaptation and resilience by collecting, detaining, retaining, and controlling or directing the release of stormwater. The present disclosure extends principles from Landscape-based Stormwater Management Practices (L-SWMPs), such as bioswales, permeable paving, and other techniques for storing and infiltrating water, to the architectural facade. The present disclosure describes a paradigm shift for the building envelope, away from the conventional “rain screen” notion that facades must repel and shed water off the building, to one that directly engages and manages water in ways that benefit broaderAtty. Docket No. 10110-24014A-W0 infrastructural and ecological systems that are vulnerable to the impacts of climate change, as depicted in Figure 13, discussed in more detail below. The present disclosure describes how the building enclosure can act as a passive sponge or “vertical bioswale” to effectively delay, store, and slowly drain excess rainwater during regular and major storm events. In this way, the present disclosure describes ways to alleviate the burden on municipal stormwater systems and the demand for intensive mechanical pumping systems that both consume significant amounts of energy and contribute to land subsidence over time, which in turn accelerates vulnerability to flooding. At the opposite extreme in hot and dry climates where water is scarce, water retention and containment intended for slow release are useful for water conservation purposes.

[0036] As further defined below with reference to Figure 1 , the present disclosure involves three interrelated scales-the micro (material) scale, the meso (component) scale, and the macro (aggregated assembly) scale-to develop an integrated understanding of how material performance and the design of modular systems can beneficially interface with buildings, landscapes, and other stormwater infrastructures.

[0037] Structures or components, and methods of making the same, employing 3DP ceramic building elements for climate adaptation by collecting, detaining, retaining, and controlling / directing the release of stormwater, are described. The 3D printed structures include a plurality of layers of printed material, such as clay. The 3D printed structures, and methods of making the same, described herein are printed large enough to be used in applications at the building or architectural scale (as opposed to object scale) for use as a building component, such as a fagade or masonry unit (i.e., building blocks). The 3D printed structures may be aggregated (i.e., stacked, hung together, or otherwise combined) to create larger scale structures. In this way, the disclosed 3D printed structures are modular building components larger than conventional brick-scaled (nominal size being 3.625” X 2.25” X 7.625”) ceramic structures currently used in buildings, as shown and described below with reference to at least Figures 15 and 17.

[0038] The 3D printed structures include geometric features, or geometries, used to collect, detain and / or retain, and control (e.g., direct) the release of water. For example, the geometric features may include surface textures designed toAtty. Docket No. 10110-24014A-W0 capture and store, or slowly release, stormwater as the stormwater flows over, into, or through the 3D printed structures. In another example, the geometric features may include infill geometries or patterns of the plurality of layers of printed material. These patterns or infill geometries create negative spaces within the 3D printed structures that are also designed to capture, store, and release stormwater. In yet another example, the geometric features may include channeling or tube-like structures that span an interior of the 3D printed structures. These channels or tubes not only provide internal structural support to allow for larger scale components being printed, but also allow water to travel through the 3D printed structures. In some cases, they act like drains or sleeves for structural elements (e.g. pipes, tubes, or other hardware) to go through for anchoring to the ground or adjacent structures. The described geometric features allow for stormwater to be detained and / or retained, or at least slowed down, so that stormwater runoff is limited in times of excess rainwater, such as during storm events, in particular major storm events.

[0039] Additive Manufacturing (AM) or 3DP is used to manufacture ceramic building components. In some examples, methods for manufacturing an architectural-scale ceramic building component or structure include inputting predetermined print parameters, based on climate conditions of where the ceramic building component will be used, into a computer, which controls the 3D printer (commercial clay printers or custom robotic extrusion systems) and then printing a plurality of layers of clay using the 3D printer to form the structure or body of the ceramic building components. The plurality of layers of clay are then fired to transform the clay into a solid state. The layers of clay make up a geometry, or have geometric features, which allow the ceramic building component to collect, detain, retain, and control (e.g., direct) the release of stormwater. In this way, when multiple ceramic building components are interconnected in a modular manner, together they act as a sort of bioswale, allowing for the collection, conveyance, filtration and infiltration of stormwater runoff. In some examples, channels or tubes span the interiors of the ceramic building components and act as drains, allowing water to freely flow between adjacent components.

[0040] The geometries of the ceramic building components are controlled and varied by the printing parameters, which are based on climate conditions. For example, inputting certain printing parameters for a certain type of climate results inAtty. Docket No. 10110-24014A-W0 one type of geometry useful for that particular climate, whereas another set of printing parameters corresponding to another type of climate results in different types of geometries. For instance, in hot climates print parameters may be selected that result in geometries that maximize sorptivity and water retention (such as exposed textures and infill), whereas in cold climates print parameters may be selected that results in geometries that minimize sorptivity and water retention (enclosed textures and infills) to avoid freeze thaw effects. In this way, the disclosed 3D printed clay elements are, by design, climatically tuned for specific climates. Thus, the predetermined printing parameters allows for intentional design of the structure, both internal and external, to meet specific goals, such as how water is detained or retained within the structure and directed out of the structure. In this way, the designs of the disclosed ceramic building components are able to be optimized depending on the printing parameters, which are based on climate conditions and goals of each use case.

[0041] Although described below in connection with a number of examples involving structural components or methods and processes for water retention, detention, diversion, and containment in modular clay 3D printed elements that interface with buildings in new construction projects (such as the facades or roofs of buildings), the disclosed structures and methods are also useful in various other applications. For example, the disclosed structures and methods may be used in retrofitting existing buildings and surrounding infrastructure. In another example, the disclosed structures may be used as stand-alone features, such as retaining walls. In yet another example, the disclosed structures and methods may be used in landscape architectural projects to achieve environmental, ecological, and social goals (e.g. seating elements). In addition to clay, the disclosed structures and methods may be used in conjunction with other materials or additives, such as other hygroscopic materials. In other examples, concrete and mortar, plastics, mud, natural aggregates, and even food byproducts may be used. In yet another example, the disclosed structures and methods may be used for aqueous filtration (e.g., water, oil, environmental contaminants, and the like), where geometries of the 3D printed structures can control levels of filtration.

[0042] Figure 1 shows a diagram depicting design parameters and performance metrics of a hygroscopic envelope on a micro-scale, meso-scale, and macro-scale in accordance with one example. A hygroscopic envelope is aAtty. Docket No. 10110-24014A-W0 building envelope - including all the building components that separate the indoors from the outdoors - that can temporarily absorb water over a specified duration of time, particularly stormwater runoff. The hygroscopic envelope may also include surrounding or adjacent features as well. As shown in Figure 1 , the disclosed structures and methods operate on three scales, or levels: micro (material level); meso (component level); and macro (aggregated assembly level).

[0043] At its core, the micro scale or level involves understanding how the clay body of the 3D printed structure or component and its chemistry, composition, and texture interacts with water. In other words, the micro scale looks at the material being used. At the micro level, a clay body (i.e., clay material) may be selected and fine-tuned for regional sourcing, functional applications (the specified requirements needed), climatic requirements (i.e., the interaction with water in diverse scenarios), and integration with a 3DP system. As mentioned above, clay can be locally sourced, which may be a factor to consider when choosing a clay material. The functional applications, or specifications, of a given project may dictate what type of material, or clay, is selected as well. Some types of clay material may perform better than others at capturing, detaining and / or retaining, and filtering water. Other material properties such as porosity and strength (both stiffness and compressive) may be considered as well depending on the desired outcomes and effects. For instance, pore size may affect both the ability to absorb water as well as durability. Performance water testing may need to be performed to see what type of adsorptive levels certain clays achieve. As stated above, clay material to be 3D printed may be climatically tuned for various climates, such as marine, warm-humid, hot-humid, cold / very cold, and hot-dry / mixed-dry. In other words, clays can be chosen based on specific ranges of temperature, relative humidity, and rainfall. Identifying specific clay bodies that would work well in different climatic regions is advantageous. For instance, a more porous clay body could hold more water, but that same clay body used in cold climates may result in cracking over time through multiple cycles of freeze / thaw. Thus, clay bodies are specified for different climate regions and tuned for appropriate performance behaviors. This level of specification is yet another manner in which the disclosed designs may be optimized. The ability of certain clay materials to integrate with 3DP systems and processes is also considered at the micro scale. Considerations include viscosity control and print behaviors. For example, anisotropic behaviorsAtty. Docket No. 10110-24014A-W0 may exist with extruded clay as it does for concrete, which may affect how the clay is 3D printed. Broader 3DP parameter considerations such as printability (rheology control), buildability, interlayer bonding, and bead shaping, apply to clay 3DP as well. Other considerations include how a clay material behaves during the drying and firing phases and how those phases affect long term performance.

[0044] In this way, printing parameters are calibrated in relation to material properties, scale limitations, and processing (drying, firing, and the like). Also included in the micro scale is looking at ways in which the clay components can interface with local biological elements that would provide additional biodiversity and health benefits. For example, the bioreceptivity (the ability of a material to be colonized by living organisms) of clay material with moss, algae, or bacteria growth (to capture carbon, clean air, self-heal, and assist with detention and / or retention of water) may be considered. This is simply achieved by incorporating live plant, moss, algae, or bacteria in / on the ceramic component (after firing) so that the living matter can capture (e.g., absorb) carbon from the atmosphere, clean air, soak up water, and self-heal. For example, moss can hold ten times its weight in water. Bioreceptivity, or the level in which living matter can thrive in / on the ceramic component, is optimized through pore control for the ceramic material, surface texture for living matter to attach to, and overall conditions by which the living matter can thrive. This may include humidity level, pH level, and light level. Living matter (especially plants) can also be placed in soil within the cavities (any openings) of the 3DP components. More broadly, this is part of biophilic integration.

[0045] The meso scale, or component level, involves the scale of the modular unit or component and techniques related to printing. At this level, the design and fabrication of the building elements are modular, employing Design for Assembly and Disassembly (DFA / DFD) principles for ease of installation and deinstallation for repair or end of life recycling. Overall component-to-component connection and tolerances are integrated as part of the design and considered against the manufacturing process. The component level focuses on specific designs of the modular building components, such as geometry, form, and surface area, to ensure that water movement and airflow can be controlled and directed. In other words, specific designs and configurations are considered to configure the components to retain, detain, divert, and hold water, as well as allowing for airflow. For instance,Atty. Docket No. 10110-24014A-W0 in conjunction with the adsorptive level of clay, additive manufacturing is leveraged at this phase (meso scale) to create customizable geometry for surface textures, infill designs, and channeling of the printed structures for water control (i.e., how and where to direct the water) and airflow. These geometric features are discussed below in more detail.

[0046] Figure 2 illustrates 3D printed surface textures in accordance with several examples. As shown in Figure 2, there are several different types of geometric features 210, such as surface textures 250 that can be used to interact with water. For example, surface textures 250 may include loops 252, as shown in the upper leftmost image of Figure 2. Loops 252 may be formed when a portion (or portions) of one of the layers 203 protrudes outward from a surface (external or internal) of the printed component or structure 200 relative to other layers 203 of the printed material. In one example, a series of loops 252 may be arranged along a single layer 203, with rows of layers 203 without loops 252 in between rows of layers 203 with loops 252. As water travels down the surface of a structure with this surface texture 250, the water would hit the loops 252 and be slowed and / or diverted from its normal downward course, thereby slowing the rate of water runoff. Water may also be caught or collected in the middle portion of the loop 252, thereby collecting water. In another example, some of the layers 203 of printed material may be configured to form surface textures 250 in the shape of droops 254, as shown in a number of images of Figure 2. Droops 254 are formed somewhat similar to the loops 252, where printed material of portions of a layer 203, or adjacent layers 203, are allowed to sag and hang downward. These surface textures 250 also interact with water in a similar fashion as the loops 252 to slow, detain, retain, and / or direct or control water runoff. Yet another example of surface textures 250 include scoops 256, which are bowl-like features formed by aligned portions of adjacent rows of print material protruding outward from the surface of the printed structure 200 relative to other layers 203. As shown in Figure 2, there are many different types of scoop 256 surface textures 250. Scoop-type 256 surface textures 250 are designed to collect and detain and / or retain water, such that as water flows down the surface of the structure 200, the water flows into the scoops 256 and is detained and / or retained there. In other examples, the scoops 256 may have openings at the bottom that allow the collected water to slowly drain out of the scoops 256. In one example, the opening at the bottom ofAtty. Docket No. 10110-24014A-W0 the scoop 256 may be in the form of a droop 254 surface texture 250. In this example, the bottom most layer 203 that makes up the scoop 256 is a droop 254 surface texture 250. In some cases, multiple types of surface textures 250 can be used in combination, as shown in Figure 2. The locations of these surface textures 250 may be predetermined based on factors such as desired water movement (i.e., to control the direction of water flow), the climate where the printed structure 200 will be used, desired aesthetics, and the like.

[0047] Infill designs or infill patterns are another type of geometric feature used to collect, detain, retain, and control (e.g., direct) the release of water. Figure 3 illustrates 3D printed infill geometries 300 (or simply infills) in accordance with several examples. In particular, Figure 3 shows top views of the infill geometries 300. Infill 300, or the internal structure of a 3D printed part, can take many forms, as shown in Figure 3. The shape and geometry of the infills 300, as well as the surface textures 250 described above, are a result of beads of material being printed in layers 203 based on a print path, which is a print parameter input into a computer, which controls a 3D printer. Figure 4 illustrates bead control for (a) surface textures 250 and (b) infill geometries 300 in accordance with several examples. As shown in Figure 4, depending on the bead path, many different infill 300 designs are possible, such as infills 300 with a grid geometry 402, an almond shape pattern 404, geometries having one or two amplitudes (symmetrical or asymmetrical) 406, 408, as well as a zig zag pattern 410. These different patterns can be adjusted for different proportions and shapes.

[0048] Both surface textures 250 and infill geometries 300 are by design to channel (move and direct), detain, or retain water. Negative spaces (between printed beads) of the infill 300 are customized to hold and direct water’s movement, as well as allow for airflow within and through the structure. In other words, the infill patterns 300 of the layers 203 of printed material span across or traverse an interior of the body of the 3D printed structure and create negative spaces within the body of the 3D printed structure. The infill patterns 300 may also extend to outside the body of the 3D printed structure. In some examples, the negative spaces are interconnected. Figures 5, 11 , and 19 illustrate infill geometry 300 designs showing printed clay as positive material 502 and negative space 504 where water can occupy in accordance with one example. The infill geometries 300 of Figures 5, 11 , and 19 are that of an almond shaped geometry 404. The leftAtty. Docket No. 10110-24014A-W0 side image of Figure 5 shows the printed clay as positive material 502, and the right side image of Figure 5 shows the negative space 504 where water can occupy. As shown in Figures 5, 11 , and 19, there can be a substantial amount of negative space 504 within an infill design 300. Depending on the desired outcome, infills 300 can be designed to slow water’s movement and customized to detain and / or retain as much water as possible. This is yet another example of how desired outcomes are taken into consideration in order to optimize the design of the disclosed 3D printed structures. As mentioned above, the geometry of the clay printed structure 200 creates negative spaces 504 in-between. These negative spaces 504 can be interconnected to allow the water to enter throughout the interior, with openings below for draining to avoid standing water conditions. Also, water cohesion creating surface tension aids water detention and / or retention for infills 300. Figure 6 illustrates sectional views showing negative spaces 602 within infill geometries 300 in accordance with several examples. Specifically, the images in Figure 6 show longitudinal or cross-sectional cuts through clay infills 300 that show the voids 602 (negative spaces) as interconnected. Figure 6, part (a), shows a cross section of the almond infill design 404. Figure 6, part (b), shows a longitudinal section of the almond infill design 404. Figure 6, part (c), shows a longitudinal section of the scoop infill design 256. As can be seen from these section views, negative spaces 602 within infills 300 allow for water detention, retention, and movement, as well as airflow.

[0049] In some examples, surface textures 250 can be incorporated with infills 300 depending on the design. Figure 7 illustrates surface textures 250, geometry of a print path, and a digital model of an infill geometry 300 design in accordance with one example. In other words, Figure 7 and 11 shows integrated surface textures 250 and infill 300, where Figure 7, part (a), is a plan view, Figure 7, part (b), is a perspective view showing surface textures 250 on the outside of the printed component 200, Figure 7, part (c), shows the geometry of the print path, and Figure 7, part (d), shows a digital model of the printed component 200. These infills 300 integrated with surface textures 250 can take many shapes. The infills 300 described and shown above with regards to Figures 2-7 may be used as a stand-alone component, or be incorporated into or part of another design, such as an external or internal structure of a larger component. The printed clay may also have different diameters in any single component, e.g. exterior geometry could beAtty. Docket No. 10110-24014A-W0 a larger extruded diameter so that the component could be more durable where interior printed paths might be smaller to optimize for water channeling, directing, detailing and / or retaining. In such cases, clay body can be specified according to diverse use cases. The different diameters of printed material and types of material enable the component to be functionally graded.

[0050] Figure 8 illustrates different views of an infill geometry 300 with scoop texture design 256 in accordance with one example. As shown in Figure 8, a printed component 200 may have a “C” shape. In this example, the clay component 200 is a 3D printed structure including a body 802 having a plurality of layers 203 of printed material. As can be seen by the images, the body 802 is printed to be used as a building component (e.g., fagade tile / panel / cladding or structure, portion of a retaining wall, or the like). The body 802 includes geometric features 210 configured to collect, detain, retain, and control (e.g., direct) the release of water. As indicated above, the geometric features 210 may include body surface textures 250, infill patterns 300 of the plurality of layers 203 of printed material, channeling within the body 802, or combinations thereof. In this example shown in Figure 8, the printed component 200 includes an infill design 300 having a symmetrical two amplitude design 408 with integrated loop 252, droop 254, and scoop 256 surface textures 250. As can be seen in Figure 8, the component 200 shown has many areas capable of interacting with water runoff, thus detailing, retaining, diverting, slowing, and directing the flow of water.

[0051] Figure 9 illustrates an example of a 3D printed ceramic component 200 having intersecting tubes 902 in accordance with several examples. As mentioned above, the geometric features 210 of the body 802 may include channeling within the body 802. In one example, the channeling within the body 802 includes at least one tube-like component 902 traversing an interior of the body 802, where at least one end of the tube-like component 902 includes an opening 904 in a generally flat sidewall 906 of the body 802. Figure 9 shows different views of a couple of different 3D printed ceramic structures 200. These structures 200 are intended for use at the building or architectural scale, being masonry units or large custom-made bricks. The structures 200 of Figure 9 have multiple tube-like components 902 within the interior of their respective bodies 802. In other words, the geometry of the ceramic building component 200 includes one or more tubes 902 spanning an interior of the ceramic building component 200. As shown, someAtty. Docket No. 10110-24014A-W0 of the tubes 902 or channels have openings 904 on a sidewall 906 of the printed component 200. Some of those tubes 902 with openings 904 on the sidewall 906 have another end that is open at the top portion of the structure 200. Other tubes 902 within the bodies 802 have openings at both the top portion of the structure 200 and the bottom portion of the structure 200, such that the tube 902 or channel runs vertically within the body 802 of the structure 200. In this way, when multiple components 200 (i.e., bricks or masonry units) having the same vertical tube-like structures 902 are stacked vertically on top of one another, the vertical tube-like structures 902 align with one another and form a drain that extends from the uppermost component 200 to the lowermost component 200. Stacking components 200 in this way is an example of aggregating a plurality of ceramic building components 200 to form one or more masonry units. In other cases, the vertical tubes 902 can also be shafts or sleeves for vertical structuring pipes for anchoring to the ground or as mounting connections to surfaces of the building (see Figure 16 and accompanying text below). Tubes 902 can also run continuously at different angles (non-vertical) across multiple units. Some of these angled tubes 902 can be opened at the top (half-pipe), to create an open trough to direct water’s movement. These open troughs may run continuously from one component 200, connecting with the adjacent component 200 to create drains. These open troughs also act to provide structural stiffness connecting the tubes 902. The curved shape of the trough prevents the expansion of frozen water (ice) from pushing on the wall of the clay trough since the walls are not perpendicular to each other, preventing freeze / thaw cycles cracking.

[0052] As can be seen in Figure 9, some of the tube-like structures 902 or channels are interconnected by webbing or layers 203 of printed material. Given that these structures 200 are difficult to print and prone to slumping during printing due to their size, the interior tubes 902 or channels and connective material (i.e., geometric features and layers 203) can be strategically placed to prevent slumping during printing of the printed material. This is another example of how controlling the geometry by way of print parameters leads to an improved 3D printed architectural-scale ceramic structure 200. In one example, as shown in Figure 9, the infill 300 can be enclosed by a printed boundary (e.g., sidewall 906) such that the infill 300 cannot be seen from the outside. In addition to preventing slumping during printing, the internal structure such as the interior tubes 902 or channels andAtty. Docket No. 10110-24014A-W0 connective material (i.e., geometric features and layers 203) provides additional strength and support for when these printed components 200 are used as building components. In other words, in one example, the internal structures allow for an improved load bearing printed component 200. As shown above, specifically designing the infill 300 patterns based on desired outcomes such as detaining and directing water results in many of the designs of infills 300 being non-uniform (i.e., non-uniform internal and external structures). Conventional components, on the other hand, designed with less thought and intentionality have a simpler, more uniform or repeating pattern, since those structures tend to be designed to simply absorb or soak up water and may not be designed to bear loads or act as structural support.

[0053] In some examples, the bodies 802 of the 3D printed structure 200 (i.e., architectural-scale ceramic building component) shown in Figures 8 and 9 are configured to interconnect in a modular fashion with other bodies 802 (e.g., structures) having a same or similar design. In this way, a plurality of ceramic building components 200 may be aggregated together to form facades or fagade tiles / panels / cladding, roof tiles / panels / cladding, or masonry units. Likewise, the 3D printed structures 200 of Figures 8 and 9 are configured to attach or mount to an existing building structure, such as a wall, roof, or beam. In other examples, the components 200 may be integrated with other functional building elements, such as drains, roof tiles, cladding, pavers, streetscape infrastructure, drainage infrastructure, and the like.

[0054] In some cases, the material and surface textures 250, such as the scoops 256 and holes of the tubes 902 or channels are able to interface with biological elements, such as moss or other plant life, especially since the disclosed ceramic structures 200 aid in the adhesion of moss. For instance, the disclosed structures 200 can incorporate hydroponics, where plant growth is accommodated in the openings 904 of the channels / tubes 902 or scooped 256 surface textures 250. In another example, the disclosed ceramic 3D printed structures 200 may be biophilic and incorporate bacteria, which, in one example, allows the structures to self-heal. Yet another biophilic integration example includes carbon capture, as described above.

[0055] Referring back to Figure 1 , the meso scale also considers module design in relation to printing, assembly (integrating circular principles of DFA / DFD),Atty. Docket No. 10110-24014A-W0 and the need for supplemental hardware or support systems, especially for interfacing with existing buildings (see Figure 16, for example). Manufacturing limits, in terms of time, labor, and cost, are also addressed at this scale, as are considerations of hybridizing the building components with other componentforming techniques (e.g., slumping, slip casting, or ram pressing). The meso scale also takes performance testing into consideration. Component performance testing with water is determined strictly by the 3D printed geometric design, and includes: sorptivity (capillary action); water detention and / or retention capacity (within and through the negative spaces of the components) (see Figure 19); water travel time (see Figure 20); and freeze / thaw cycles. Computational analysis (Finite Element Analysis (FEA)) is used to determine stiffness during the printing process, and destructive tests are performed for post-fired components to evaluate compressive strength for multi-unit assembly design. These and other variables, such as those discussed above, are considered when choosing printing parameters to input into the computer, which controls the 3D printer to print the disclosed structures (ceramic building components).

[0056] Still referring to Figure 1 , the macro level involves the scale of the component assembly (e.g., fagade assembly) as an envelope and how the component assembly and envelope connects, and interacts with, the building, the site, and the city. Considerations at this level involve how various units combine with each other (e.g., as a unified drainage system) to affect rates of water runoff, and what the implications are for the urban scale (see Figure 15). Strategies may be considered for variation across different exposures, site orientations and contexts, such as how an individual system of components meets / joins / abuts a roof, the ground, or transitions to other drainage systems, including L-SWMPs, in the immediately adjacent landscape. Another consideration at the macro level is how modular units might double as performative landscape elements, e.g., pervious pavers for parking areas, to improve landscape performance for infiltration.

[0057] At the assembly level, modular units are aggregated as a building system for a fagade, roof tiles, or masonry units. Design of the system identifies component-to-component fit and necessary tolerances when assembled. Mounting systems and details may be customized and fabricated but may also employ nowAtty. Docket No. 10110-24014A-W0 known or later developed mounting hardware (see Figure 16). Sequences of assembly or construction techniques may be developed specific to each system.

[0058] Customized building envelope systems with clay 3DP components may be designed for one or more applications, including: building fagade retrofits; evaporative cooling; sun-shading; acoustic control; fireproofing; water control; passive irrigation; and aqueous filtration. These applications may be integrated with other functional building systems such as drainage from roofs or other means of channeling water such as scuppers, pipes, or drains, as well as integrated into infrastructural elements for holding water such as cisterns, passive irrigation systems, or other forms of green infrastructure. Biophilic considerations with moss, algae, and bacteria for water detention and / or retention, plant growth, carbon capture and self-healing properties may also be integrated. Clay body specification and surface textures contribute to biophilic integration, e.g. clay body porosity and / or ridges and crevasses from 3D printed layers enhance biological adhesion.

[0059] As shown in Figure 1 , a life cycle assessment is interrelated to each of the micro, meso, and macro scales. Specifically, parallel to the three scales are specific Life Cycle Analysis (LCA) evaluations that include the full life cycle of clay as a building material, from extraction and processing to integration with additive manufacturing, to end-of-life recycling, and reuse. The disclosed structures and methods of making the same focus on fired, but unglazed clay, which can be fully recycled. Similarly, unfired printed clay objects can be crushed, rehydrated, and fully re-used to make new printed objects.

[0060] As mentioned above, geometries 210 (surface textures 250, shapes, infills 300, etc.) of the printed structures or building components 200 are controlled and varied by the printing parameters, which are based on climate conditions, for example. As such, the material used to 3D print a structure for use as a building component is selected based on climate conditions where the structure is to be used as the building component. In this way, the printing parameters may be predetermined, based on predetermined climate conditions (i.e., the climate where the 3D printed ceramic building component is to be used). This is yet another example of how controlling the geometry by way of print parameters leads to an improved 3D printed architectural-scale ceramic structure.

[0061] Figure 10 shows a diagram depicting climate specificity in relation to the three scales shown in Figure 1 . As mentioned above, 3D printed componentsAtty. Docket No. 10110-24014A-W0 may be, by design, climatically tuned for specific climates, including marine, warm- humid, hot-humid, cold / very cold, and hot-dry / mixed-dry. Figure 10 shows three extreme climates where the disclosed structures and methods will have the most impact - hot-humid, cold / very cold, and hot-dry. The two other climates, marine and warm-humid, are envisioned to be a combination of the three shown in Figure 10, catering to specific ranges of temperature, relative humidity, rainfall, and application. As shown in Figure 10, knowing the climate in which the disclosed structures will be used offers a blueprint for designing the most appropriate 3D printed component. For example, identifying the desired climate allows a specific type of clay body to be chosen (micro scale), allows printing parameters and a component design to be selected for the desired climate (meso scale), and provides options for how to assemble and use the 3D printed component for the specific climate (macro scale).

[0062] Figure 11 illustrates an infill geometry design with print parameters and water test results in accordance with one example. Figure 11 is an example of the type and level of detail that is available given certain print parameters. As shown in Figure 11 , part (a), a plan view of the infill design 300 is shown, indicating specific dimensions between amplitudes of the beads of material (i.e., of the almond shape design 404). The type of clay body used, nozzle size, step height, and print parameters are shown at the top of Figure 11 , in part (b). A digital model of the print path, including volume, as well as a model of the actual clay print, also including volume, is also shown in parts (c) and (d) of Figure 11 , respectively. Cross sections at three different locations, as well as the negative volume around the clay where water can occupy, including volume, is also shown in parts (e) and (f) of Figure 11 , respectively. Figure 11 , part (g), also depicts water test results, which allows for the performance and effectiveness of the design to be evaluated. Armed with this knowledge, 3D printed ceramic building components may be designed and manufactured to achieve the desired outcomes discussed herein.

[0063] Given all the variables and material characteristics of clay that directly impact a component’s usefulness, the composition of the clay material used for 3DP may be customized. However, in other examples, commercially available clay may be used.

[0064] Referring to Figure 12, a flow chart for a method 1200 of manufacturing an architectural-scale ceramic building component in accordanceAtty. Docket No. 10110-24014A-W0 with one example of the present disclosure is illustrated. The flow chart as described herein may be used with any of the ceramic structures or methods for manufacturing an architectural-scale ceramic building component described herein. Additional, different, or fewer acts may be included.

[0065] In a first act 1202, printing parameters may be input into a computer, which controls a 3D printer. For example, a script containing data regarding size, shape, print path, and the like for the desired structure may be input. In one example, another act 1203 may include selecting the printing parameters based on predetermined climate conditions. For example, using a diagram, such as the one shown in Figure 10, depicting climate specificity in relation to the three scales allows printing parameters to be selected based on a particular climate.

[0066] In a second act 1204, a plurality of layers of clay may be printed by the 3D printer. The plurality of layers of clay have a geometry, such as the geometries described above, configured to collect, detain, retain, and control (e.g. direct) the release of water, such as stormwater. In one example, another act 1205 may include controlling the surface textures and infill geometries based on the printing parameters.

[0067] In a third act 1206, the plurality of layers of clay are fired to form the ceramic building component.

[0068] Figure 13 illustrates how conventional rain screens function to repel water away from the building facade in contrast to the intended performance of a hygroscopic envelope system in accordance with one example. The left side image of Figure 13, part (a), shows a traditional rain screen 1302 attached to the side of a building 1304, which is designed to repel and shed water away from the fagade of the building 1304. As seen in Figure 13, part (a), as rain and wind contact the building 1304, the rain travels down the building 1304 and rain screen 1302 in a sheet flow 1306. In these circumstances, the outflow of stormwater runoff can be significant. In contrast, the right side image of Figure 13, part (b), shows a hygroscopic envelope, where the traditional rain screen is replaced by 3D printed ceramic structures 1308 disclosed and described above (such as, for example, the components / structures 200 of printed layers 203 having geometric features 210, such as surface textures 250 and infills 300 including tubes 902). As shown in Figure 13, part (b), as the rain and wind contact the building 1304, the rain travels over, in, and through the 3D printed ceramic structures 1308, which actAtty. Docket No. 10110-24014A-W0 to collect, detain, retain, and slowly release the rainwater over time in a controlled and directed manner. In this way, rather than a sheet flow 1306 of rainwater, the rainwater is slowed and held via cohesion and adhesion within the 3D printed ceramic components 1308, thereby minimizing and / or slowing the rate of stormwater runoff.

[0069] Figure 14 illustrates how water interacts or behaves with the disclosed ceramic components at the three described scales, including at the micro scale (Figure 14, part (a)), at the meso scale (Figure 14, part (b)), and at the macro scale (Figure 14, part (c)). Each diagram shows where water could potentially be detained or slowed. For instance, Figure 14, part (a), illustrates water moving through, and being detained or slowed within, pores (i.e., microstructure of the clay, or micro level). Figure 14, part (b), illustrates water moving through, and being detained or slowed within, the negative space between the printed layers of clay (i.e., the meso level). Figure 24, part (c), illustrates how water can move from one component to adjacent components through the 3DP geometries, effectively channeling, directing, and slowing storm water runoff (i.e., the macro level).

[0070] Ceramic components may be assembled as a facade system, as shown in Figure 15, where multiple ceramic components may be stacked or arranged adjacent to one another to form the fagade system. Figure 15 illustrates two fagade systems or assemblies for two different climates. Figure 15, part (a) on the left is for a cold / very cold climate, where two types of clay are compared to test viability for the full-scale prototype. Figure 15, part (b) on the right is for hot / wet climate, where diverse variations of components direct water from one component to another downward, to slow and detain water. Mounting frames, such as those shown in Figure 15, may be custom manufactured with commercially available brackets for mounting.

[0071] Figure 16 illustrates printed geometries and designs to account for mounting details, integrations of pipes (through tubes), and for protecting ceramic components using gaskets in accordance with several examples. More specifically, Figure 16 illustrates the various ways 3DP ceramics can be geometrically configured for specific mounting scenarios. Figure 16, part (a), in the top left image shows a plan view of a component with tubes 902 having a built-in design 1602 to receive a mounting clip 1604. Figure 16, part (b) (right top image) and part (d) (right bottom image) show how the clip 1604 slides into a slot 1606 ofAtty. Docket No. 10110-24014A-W0 the built-in design 1602 (with reinforced double layer of extruded clay) and is buffered with a rubber gasket 1608 to protect the ceramic component from the metal clip 1604. Figure 16, part (c), in the lower left hand corner image shows how a tube 902 may interact with hardware, such as a pipe 1610, where the tube 902 is designed as a sleeve to receive the hardware.

[0072] Figure 17 shows two large-scale landscape / infrastructural scale components 200 (each with a different clay body having different geometries). Figure 17 also illustrates the ability of the tubes geometry 902 to be printable in tall and large-scale components 200. A person is included in Figure 17 for scale reference. Components, such as the components 200 shown in Figure 17, may be customizable: the tubes 902 can be closed off to create cisterns that hold water, the tubes 902 can direct and channel water, or the tubes 902 can create cavities to be filled with dirt for plant habitats. The negative space (cavities) can also receive dirt, soil, sand or other biomass as fillers. For instance, diatomaceous earth can be incorporated into the filler (of any material) for landscape components that meet the ground to serve as natural insecticide or pest control. Diatomaceous earth also helps to absorb and retain water, and can filter impurities. Fillers will also close cavities in the component to prevent faunas from inhabiting inside (unless designed to house specific faunas for ecological purposes). Landscape components can be used as a retaining wall, marking boundaries (e.g. fencing), seating, or any outdoor infrastructure applications. As shown in Figure 17, the size of the printed components 200 allows for use in the architectural or building scale (as opposed to object scale) for use as a building component, such as a fagade or masonry unit (i.e., building blocks). The printed components 200 are also large enough to be used for other, diverse architectural applications, such as landscape components mentioned above. For example, in one embodiment, a printed component 200 of a fagade panel with disclosed infills 300 may have an overall width in the range of 12 inches to 24 inches, an overall depth in the range of 1 .5 inches to 7 inches, and an overall height in the range of 9 inches to 14 inches (i.e., 12”X1.5”X9” to 24”X7”X14”). In another example, a printed component 200 having internal tubes 902 such as those shown in Figures 9 and 17 may have an overall width in the range of 9 inches to 24 inches, an overall depth in the range of 3 inches to 16 inches, and an overall height in the range of 8 inches to 20 inches (i.e., 9”X3”X8” toAtty. Docket No. 10110-24014A-W024”X16”X20”). These are just two example ranges. Other sizes and proportions, such as larger or smaller, may be used.

[0073] Figure 18 illustrates samples of different densities of printed material to maximize surface area and through ventilation for evaporative cooling purposes in accordance with several examples. Evaporative cooling involves lowering air temperature as water evaporates into the air. In this way, evaporative cooling is contingent on maximizing surface area for water to evaporate from. Figure 18 illustrates the variations of geometry that maximize surface area, but, relative to the almond infills 404, have larger negative spaces between the printed material for the purpose of evaporative cooling when the material is wet (i.e., the spacings and openings between the printed material that allow air to travel through). The volume can be of any measurement, or integrated with other component designs as an interior of the component to facilitate evaporative cooling. Evaporative cooling with ceramics, clay-based material (e.g. bricks), or clay jars with water inside (whereby water seeps through the material for evaporation) may be known. However, the present disclosure provides for the customization in 3DP geometries and controlling the optimization of material surface exposure to evaporation and openings to facilitate air movement through the material from the hot side to the cool side, which solves problems and improves upon the related art. The images in Figure 18 show orthogonal layers of printed clay material, whereby designs can vary in geometry and overall form as a volume.

[0074] Figure 19 illustrates additional examples of print paths, surface geometries, and digital models in accordance with two examples. Figure 19 expands upon Figure 7 above, showing different design configurations for a toolpath (i.e., print path, or pre-defined set of instructions that dictate the movement of the 3D printer). Figure 19, part (A) on the left, shows how a variable alternating stacked toolpaths can create a porous, constant infill structure with hygroscopic capacity. The geometry of the toolpath can be tuned and adjusted to detain water at different rates. The diagram of part (A) of Figure 19 shows the toolpaths at left, the three-dimensional view of the extruded clay in the middle, and the negative space of the voids between the clay at right. Figure 19, part (B) on the right, shows an alternate design of a variable infill that extends the infill geometry outwards to create larger scoops that collect and direct water into the infill structure. The diagram of part (B) of Figure 19 also shows the toolpaths at left, the three-Atty. Docket No. 10110-24014A-W0 dimensional view of the extruded clay in the middle, and the negative space of the voids between the clay at right.

[0075] Figure 20 illustrates an infill design that can perform as an evaporative cooling device in accordance with one example. As mentioned above, the disclosed ceramic infill structures are operable to perform environmentally as an evaporative cooling device. In one example, the densely packed, porous infills 300 may be supplied with water from a drip irrigation system 2002 (or with stormwater). The dense infill 300 provides maximal surface area for water to coat and soak into the ceramic material. As hot air moves through these modules on one side, the water on the surface of the ceramic infill 300 evaporates, absorbing heat from the air and thereby lowering the temperature of the air as it passes through the component. Particularly in hot and dry climates, this technique can be an effective means of passive cooling, reducing the need to rely entirely on energy-intensive mechanical air conditioning. The capacity of 3D printing and the innovative infill designs 300 disclosed herein to maximize surface area and air ventilation combined with the material properties of the ceramic make this design particularly effective. Here again, the infill designs 300 are predetermined and can be finetuned (via printing parameters) based on a desired outcome, such as, for example, evaporative cooling.

[0076] Figure 21 illustrates infill designs that can perform as landscape elements for retaining and / or detaining stormwater in accordance with two examples. The disclosed ceramic infill structures are also operable to perform as permeable hardscape surfaces, such as a plurality of paver modules 2102, and free-standing planters / knee wall 2104. Structured voids 2106 within these modules or components allow for controlled water infiltration, slowing the rate at which precipitation enters subgrade soil 2108 profiles. Regulating permeability helps reduce surface runoff and erosion by providing additional time for filtration to occur during rain events. The disclosed module or component designs minimize impermeable surface coverage, replacing what would typically be a solid paver or otherwise impermeable surface material, such as concrete or asphalt, with a network of ceramic capillaries and void spaces 2106 that allow rainwater to slowly penetrate into the soil 2108 below or can be filled with biomass 2110 or construction aggregate to provide additional stability and decrease the potential for suspended air voids. The negative spaces (cavities) and the overall geometry ofAtty. Docket No. 10110-24014A-W0 these landscape-scale modules or components also create space for plants 2110, which help to reduce urban heat, capture carbon, and clean air, while potentially contributing to increased biodiversity.

[0077] The 3D printed structures and methods of manufacturing the same described herein may be used to improve climate adaptation and resilience by offering ceramic components for use at the building or architectural scale. For example, each component may be used on its own or aggregated with other components such that an array of components offer a larger-scale stormwater runoff collection and retention system, where the components directly manage water in beneficial ways, as described above. The disclosed architectural-scale ceramic building components provide an alternative way to deal with stormwater runoff. The ability to control 3D printing parameters that directly affect the resultant geometries to have specific desired outcomes, which in turn directly affect the management of stormwater runoff, may help enable widespread adoption of the disclosed structures, methods, and systems. The physical properties and use cases of clay described above offer tremendous advantages over other construction materials, such as concrete which has higher embodied energy.

[0078] While the present invention has been described with reference to specific examples, which are intended to be illustrative only and not to be limiting of the invention, it will be apparent to those of ordinary skill in the art that changes, additions and / or deletions may be made to the disclosed embodiments without departing from the spirit and scope of the invention.

[0079] The foregoing description is given for clarity of understanding only, and no unnecessary limitations should be understood therefrom, as modifications within the scope of the invention may be apparent to those having ordinary skill in the art.

Claims

Atty. Docket No. 10110-24014A-W0What is Claimed is:

1. A three-dimensional (3D) printed structure, the structure comprising: a body including a plurality of layers of a printed material, the printed material traversing an interior of the body, wherein the body is printed at architectural scale for use as a building component, and wherein the body includes geometric features configured to collect water, detain water, and direct the release of water.

2. The structure of claim 1 , wherein the printed material comprises clay.

3. The structure of claim 1 , wherein the geometric features comprise body surface textures, infill patterns of the plurality of layers of printed material, channeling within the body, or combinations thereof.

4. The structure of claim 3, wherein the body surface textures comprise portions of a set of layers of the plurality of layers protruding outward from a surface of the body relative to other layers of the plurality of layers.

5. The structure of claim 3, wherein the infill patterns of the plurality of layers of printed material create negative spaces within the body.

6. The structure of claim 5, wherein the negative spaces are interconnected.

7. The structure of claim 5, wherein the negative spaces are configured to maximize surface area and detain water, such that the structure is operable to perform evaporative cooling.

8. The structure of claim 3, wherein the channeling within the body comprises a tubelike component traversing the interior of the body, wherein at least one end of the tube-like component comprises an opening in the sidewall of the body.

9. The structure of claim 1 , wherein the geometric features prevent slumping during printing of the printed material.

10. The structure of claim 1 , wherein the building component includes a fagade tile, a roof tile, or a masonry unit.Atty. Docket No. 10110-24014A-W011. The structure of claim 1 , wherein the body is configured to interconnect in a modular fashion with other bodies having a same or similar design.

12. The structure of claim 1 , wherein the material is selected based on climate conditions where the body is to be used as the building component.

13. The structure of claim 1 , wherein the material is configured to interface with biological elements.

14. A method of manufacturing an architectural-scale ceramic building component, the method comprising: printing, by a three-dimensional (3D) printer based on printing parameters, a plurality of layers of clay to form a body, wherein the plurality of layers of clay have a geometry traversing an interior of the body, the geometry being configured to collect water, detain water, and control the release of water; and firing the plurality of layers of clay to form the ceramic building component.

15. The method of claim 14, wherein the geometry comprises surface textures, infill geometries of the ceramic building component, or combinations thereof.

16. The method of claim 15, further comprising controlling the surface textures and infill geometries based on the printing parameters.

17. The method of claim 15, wherein the infill geometries comprise interconnected negative spaces within the body of the ceramic building component.

18. The method of claim 14, wherein the geometry of the ceramic building component comprises one or more tubes spanning an interior of the ceramic building component.

19. The method of claim 14, wherein the geometry of the ceramic building component prevents slumping during the printing of the ceramic building component.

20. The method of claim 14, further comprising selecting the printing parameters based on predetermined climate conditions.

21. The method of claim 14, further comprising aggregating a plurality of ceramic building components to form facades, roof tiles, or masonry units.

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