Design exploration of historical structures as inspiration for 3D Concrete Printing (3DCP)

The compression-dominant behavior of unreinforced concrete demands architectural forms that efficiently propagate loads through compression. By studying historical structures that rely primarily on compression under deadloads such as arches, vaults, and domes—this research extracts lessons applicable to 3D concrete printing (3DCP).

The project identifies geometries whose structural principles align with 3DCP’s material behavior and fabrication constraints. Selected historic examples are analyzed in terms of their structural logic, materials, and construction techniques, focusing on how foundations, walls, and roofs were shaped to maintain stability without reinforcement or formwork.

Ultimately, insights from these compression-based structures inform new approaches for affordable, sustainable housing and emergency shelters using 3D-printed concrete that exploits geometry, rather than reinforcement, while eliminating the use of formwork.

Author:

Gonçalo Marques Duarte

Committee Members:

Jose Pinto Duarte, Ph.D.

Nathan Brown, Ph.D.

Ali Memari, Ph.D.

Exploring slicing strategies

From a 3d printing standpoint, where the material is deposited in continuous layers, the construction strategies presented for the arched roofing system of historic precedents can be summarized into: (i) Roman/Radial; (ii) Corbeling/Horizontal; (iii) Nubian/Inclined.

Radial printing requires the nozzle to be tangent to the curve of the vault, in a radial orientation, leading to layers with wedged sections, which contrasts with Corbeling and Nubian printing that considers the nozzle to be perpendicular to the layers, which are respectively horizontal and diagonal, resulting in layers with cross-sections of constant height.

Design space exploration of vaults

Design space exploration generates multiple design variations to evaluate form, performance, and buildability. By systematically varying geometric parameters, it helps identify optimal structural and aesthetic solutions. This process promotes innovation, reveals hidden relationships between design and fabrication, and supports data-driven decision-making.

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