The workflow begins within the context of the overall architectural project (often developed in a BIM environment using Revit). In complex projects, the building facades consists of intricate connections that require realistic and rapid visualization for architectural and functional approval.
The use of FDM 3D printing prototyping has become a strategic support tool for this design phase.
Once the 3D modeling is completed in Revit, the process transitions to the CAM modeling software Autodesk Fusion, detailing the following workflow stages:
1. Engineering and Detailed Modeling in Autodesk Fusion
Fusion enables parametric and mechanical modeling of a "node sample" (typically a T-joint or cross-joint section showing the intersection between mullion and transom, complete with the opening mechanism; however, any other detail can be created within the machine’s size limitations) for custom components that are not commercially available off-the-shelf, and whose production through traditional industrial techniques would require custom molds or dies with significantly longer lead times.
A. Parametric Setup and Sketching
A phase that allows model dimensions to be set dynamically without having to redraw the model. These software programs enable high-precision tolerance settings to ensure full compatibility between various parts and machining geometries (holes, slots, logos, etc.).
B. Component Modeling (Assembly)
The prototype is modeled as an assembly comprising multiple bodies, which are subsequently converted into independent solid components simulating metal profiles, gaskets, kinematic accessories, and glazing.
Next, for samples featuring moving components, joints (e.g., Revolute or Slider) are applied to kinematically test movements and verify the absence of geometric collisions.
2. Preparation for FDM 3D Printing: Slicing Strategy
Once the digital model is defined, the FDM (Fused Deposition Modeling) technology requires an intelligent breakdown for the printing phase to guarantee part solidity, optimize printing, and minimize the use of support structures.
For the printing phase, FDM technology requires export from Fusion into formats compatible with the slicing software, such as STL or 3MF.
Each real-world component requires a compatible surrogate material that mimics its original characteristics as closely as possible, selected from an archive of historical material test data.
3. 3D Printing and Post-Processing
Every print job requires a code generated by specific software, enabling sequential or simultaneous production (if a multi-material/multi-color system is available). Once printing is complete, the parts are removed from the build plate and finished.
4. Final Assembly of the Physical Sample
The workflow concludes with the assembly and securing of all parts of the mechanical prototype.
The final result is a fully functional 1:1 scale (or reduced scale) architectural-mechanical model. This prototype allows designers to visually test aesthetics, detail ergonomics, and assembly processes prior to initiating the costly production of industrial extrusion dies. Above all, it reduces decision-making lead times within the project lifecycle, particularly during the production phase of the subsequent performance mock-up to be tested in laboratory conditions.
Firm Expertise and Case Study
In recent years, the Firm—through 3D Modeler / Designer Dario Cattivelli—has developed this technology to address critical phases of construction site processes using custom systems. To this end, an integrated laboratory has been set up within the office, equipped with several FDM and SLA printers operating in a protected and controlled environment.
As an example of this technological process, reference was made to the MIRE Pediatric Hospital in Reggio Emilia, designed by BININI Partners, for which Studio Cattivelli serves as Works Director (DO) for the facades. The project utilizes several high-performance systems, including large-scale thermally broken window frames and double-glazed units integrated as components of double-skin facades.
