Abstract Integrating smart technology and advanced materials in the construction industry has revolutionized traditional building practices, enhancing efficiency, sustainability, and overall performance. Researchers and professionals in the construction sector have shown significant interest in three-dimensional concrete printing (3DCP) for automating structural engineering tasks. Despite its potential as a sustainable solution to modern construction issues, there is a lack of research on the thermal insulation performance of three-dimensional printed concrete (3DPC) building envelopes, and the potential for integrating foam concrete (FC) to enhance energy efficiency has not yet been studied. This paper presents a numerical analysis examining how different infill geometries affect the thermal performance of 3D-printed foam concrete (3DPFC) lattice envelopes. Six lattice structures were designed with identical thickness, height, length, and comparable insulation areas. The effects of the contact (intersection) area of webs with the interior face shell, webs, and infill rows on the thermal performance of granularly insulated envelopes were studied. The effectiveness of insulation was also established. The findings indicate that the thermal transmittance of 3DPC envelopes correlates directly with the contact area of the webs and the interior surface, with U-values ranging from 0.151 W m2·K to 0.652 W/m2·K. Notably, the absence of direct connections between exterior and interior surfaces enhances insulation efficiency, with double-row structures achieving up to 94% insulation efficiency. However, when there is a direct connection between the two surfaces, the thermal performance of these envelopes is mainly affected by the contact (intersection) area of the webs with the interior face rather than the number of webs. By integrating foam concrete and double-row walls, this study demonstrates an innovative approach to reducing thermal bridging and improving energy performance in 3D-printed construction. The results offer novel insight into optimizing the thermal behavior of 3DPC systems for sustainable building practices.
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