Controlling Roughness: 3D Printed Bio-Circular Materials For Acoustic Performance

A research project by 4TU Design United at Delft University of Technology explores how surface texture in bio-circular materials can be precisely controlled through 3D printing. The project, Controlling Roughness, shows how designers can use roughness as a functional feature rather than a by-product.

Designing With Roughness

Bio-circular materials, made from renewable or waste-based sources, help reduce the embodied carbon of buildings. However, they are often difficult to process and standardise. This limits their use in architecture. In the project, the researchers demonstrate how additive manufacturing can address this challenge. They worked with a bio-circular material developed by Studio Omlab. By adjusting 3D printing parameters such as layer height, extrusion rate and toolpath, they created different surface textures during production. This approach removes the need for extra finishing steps.

Acoustic Performance Through Material Design

Surface texture strongly affects how materials absorb or reflect sound. This makes it an important factor in architectural acoustics. The team tested this relationship by measuring the acoustic absorption of several 3D printed samples. Each sample had a different level of roughness. The results show a clear link between printing parameters and acoustic performance. Rougher surfaces improved sound absorption, while smoother ones reflected more sound.

Based on these findings, the team developed a series of modular blocks. Each block offers a different level of acoustic absorption, ranging from low to highly effective. Designers can use these variations to fine-tune sound behaviour in a space.

New Opportunities For Sustainable Design

This project highlights the design potential of combining bio-based materials with digital fabrication. Instead of forcing these materials into standard industrial forms, the researchers embrace their natural characteristics.

By controlling roughness, they add performance directly into the material. This reduces the need for additional layers or acoustic panels. It also supports more efficient and potentially circular construction systems.

The approach offers new possibilities for architects and interior designers. It is especially relevant for spaces where acoustics matter, such as offices, schools and public buildings. The results show that roughness can become a valuable design tool in sustainable architecture.

Source & photos: 4TU Design United