Towards low-carbon construction: Nature-inspired internal patterns for thermal insulation in lightweight concrete component cast using 3D-printed formwork

The building sector is responsible for nearly 39% of global greenhouse gas emissions, emphasizing the need for innovative low-carbon materials to achieve climate neutrality by 2050. Lightweight concrete, when optimized for thermal insulation, emerges as a promising solution. However, conventional cavity patterns such as honeycomb and grid designs offer limited disruption of heat transfer pathways. To overcome these limitations, this study introduces a nature-inspired Voronoi cavity design, developed via a “Scan to Model” technique derived from the microstructure of bamboo fibers. Computational simulations and experimental testing demonstrate that the irregular Voronoi geometry enhances thermal resistance, achieving up to 52.9% reduction in conductivity compared to solid blocks. Beyond performance, this work exemplifies a scalable nature-based solution (NBS) for low-carbon construction, supporting EU climate goals and offering potential integration in circular design workflows. By combining bio-inspired geometry, additive manufacturing, and porosity-driven optimization, this approach promotes material efficiency, waste minimization, and climate-adaptive building design.