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Advanced Additive Manufacturing Across Material, Scale, Dimensions Towards High-Performance Structure

Teng Teng (Dissertation, 2026)

Teng Teng Dissertation
Architectural-scale MMAM self-morphing pavilion prototype after full assembly and removal of temporary supports. The canopy modules were printed flat using multiple materials with programmed drying-driven deformation, allowing each module to self-fold into a curved funicular geometry during post-print drying. The self-morphed modules were zip-tied into a continuous canopy surface and supported by four columns under the intended design load condition, demonstrating the pavilion-scale feasibility of multi-material self-morphing construction. Image Credit: Teng Teng
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Teng Teng Dissertation
Architectural-scale MMAM self-morphing pavilion prototype after full assembly and removal of temporary supports. The canopy modules were printed flat using multiple materials with programmed drying-driven deformation, allowing each module to self-fold into a curved funicular geometry during post-print drying. The self-morphed modules were zip-tied into a continuous canopy surface and supported by four columns under the intended design load condition, demonstrating the pavilion-scale feasibility of multi-material self-morphing construction. Image Credit: Teng Teng

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DISSERTATION

The dissertation develops a scalable framework for multi-material additive manufacturing (MMAM) in architecture and construction to fabricate high-performance, functionally graded structures. The research addresses the mismatch between complex architectural designs, spatially varied performance demands, and manufacturing methods that still rely largely on single-material processing and multi-part assembly. This mismatch reduces manufacturability, increases material and energy use, and produces waste through formwork, post-processing, and assembly. To address this gap, the dissertation advances MMAM from laboratory-scale prototyping toward architectural-scale deployment. The work integrates gantry and robotic fabrication platforms, unified numerical control for multi-material deposition, slicing and toolpath strategies for graded components, design methods for functionally graded objects, and characterization workflows that connect material composition, mixing behavior, interfacial quality, and printed performance. Case studies from product to architectural scale demonstrate how programmable material distribution can improve manufacturability, tailor local performance, and reduce material use in architectural fabrication.

Teng Teng