Abstract
Artificial habitat structures are increasingly used for biodiversity conservation, yet their designs often lack the integration of sustainable engineering principles. In this study, we present the development and evaluation of an artificial bumblebee nestbox designed to support Bombus terrestris colonies while minimising environmental impact across its lifecycle. A thermal simulation model and field testing conducted in 2023 and 2024 were used to assess four design iterations (V1–V4). We tested design refinements including: cavity-wall insulation, condensing stalactite structures, entrance geometry, and design for additive manufacturing to reduce material use, build time and post-processing. Field results demonstrated that double-walled designs, materials with high albedo colours and increased material use all contribute to more thermally stable colony conditions. The simulation outputs correlated strongly with the empirical data, validating the model as a tool for improving the thermal behaviour prior to physical prototyping. Humidity analysis suggested that the designs that reduced the temperature fluctuation the most performed least effectively at managing humidity levels. Manufacturing analysis indicates that the refined V4 design reduces filament use by 38% and eliminates support material, enhancing sustainability and economic viability. The development of BeeBox demonstrates how ecological requirements, material selection, and AM-driven design for sustainability can be balanced to produce a successful low-impact habitat solution.