3D printing of reinforced clay

Project data 

Short description

Additive manufacturing with earth-based materials like clay is gaining importance due to its sustainability and technological potential. However, the material’s low tensile strength limits both the achievable geometries and structural performance of 3D-printed components. While current approaches enable basic earth 3D-printing, self-supporting structures and overhangs remain a significant challenge without external support structures. This research aims to overcome these limitations by investigating mechanical reinforcement through the integration of natural fibers in the form of short fibers, fiber-fabrics and continuous long-fibers during the printing process. The central hypothesis is that embedding fibers can enhance both form freedom and structural integrity. The project focuses on developing an optimal interaction between earth-based materials and fiber reinforcement. Key aspects include digital strategies for precise fiber placement and the systematic evaluation of different fiber types and orientations.

Mechanical testing will assess the tensile performance of the fiber-reinforced earth matrix and provide insights into the fiber–matrix interaction. With these preliminary examinations a digitally controlled, dual-material extrusion based printing process is the aim. The feasibility of the proposed composite system will be demonstrated through applications like overhangs and load-bearing elements. Psychological success factors and implementation barriers will be assessed experimentally to identify and prevent acceptance problems. Ultimately, the project seeks to establish a novel, digitally driven construction method for sustainable and structurally enhanced earth architecture.