Investigation of Additively Manufactured Glass Components for the Built Environment

Additive manufacturing (AM) has transformed the production of metals, polymers, and ceramics, yet its application to glass remains in its early development stage. The high processing temperatures, complex viscosity–temperature relationship, and brittleness of glass have long hindered the development of scalable fabrication routes. This dissertation investigates the feasibility and potential of additively manufactured glass components for the built environment, with a specific focus on enhancing flat glass by 3D-printing structural or functional features directly onto glass plates. The research combines material science, experimental testing, and architectural design to establish a comprehensive framework for evaluating AM glass. Theoretical analyses define the thermal and mechanical boundary conditions for glass-glass fusion, while a set of non-destructive and destructive experiments—including bending, shear, indentation, and optical tests—assess the mechanical performance and bonding quality of representative specimens. Finite element modelling complements the physical experiments to identify key process–structure relationships and load-transfer mechanisms. Building on these findings, several design prototypes demonstrate how AM glass can be integrated into architectural applications such as stiffened façade panels, point fixings, and glass blocks. In addition, the implementation of AM glass within existing glass production and processing workflows is discussed, highlighting practical pathways for industrial integration and upscaling. The results confirm that Am glass components can contribute measurable stiffness and structural functionality, provided that bonding and thermal management are precisely controlled. By linking experimental evidence, numerical simulation, and design exploration, this research advances the understanding of additive glass fabrication and establishes foundational strategies for integrating AM glass components into future architectural and industrial systems.