SIM-AM 2025

Layer-wise Form-finding of Global Geometry and Print Path of Vaulted Structures based on Graphic Statics and Traditional Masonry Methods

  • Chovghi, Frederic (Technical University of Munich (TUM))
  • D'Acunto, Pierluigi (Technical University of Munich (TUM))

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This study presents a fabrication-aware form-finding method for generating print layer-wise self-supporting vaulted structures through robotic extrusion 3D printing. Based on the principles of graphic statics, this work reconsiders historical masonry techniques using contemporary computational design and fabrication methods [1,2]. The proposed design approach simultaneously defines both the global geometry and the print path of the structure iteratively layer by layer, ensuring compression-dominant internal load transfer throughout the fabrication process. The overall form-finding routine is based on Combinatorial Equilibrium Modelling (CEM) [3], enabling the iterative control of internal normal force distributions layer by layer, considering one closed layer per iteration. By embedding structural, material, and fabrication constraints into the design workflow at both the final and the individual layer-wise states, the method strategically confines the design space to enable feasible, continuous, and formwork-free robotic fabrication using material compositions with high compressive strength relative to their lower tensile strength like concrete or earth. To expand the design flexibility of the form-finding process, the proposed method incorporates an aramid cord following the print path, allowing the printed layers to resist tension in the axial direction. The design method is validated through its application to a series of design studies and small-scale prototypes using cementitious mortar or an earth material. The prototypes demonstrate the feasibility and structural integrity of the fabricated vaulted structures, underscoring the potential of this interdisciplinary approach to bridge historical construction techniques with contemporary structural form-finding and digital fabrication methods. The work contributes to the development of material-efficient, low-waste approaches for future construction practice. [1] Chovghi, F., Richter, D., Dörfler, K., and D’Acunto, P. Reconsidering the historical cap ceiling: layerwise form-finding of self-supporting vaulted structures for in situ 3D printing. Proceedings of the IASS 2024 Symposium. (2024). [2] Chovghi, F., Richter, C., and D’Acunto, P. Fabrication-Aware Structural Form-Finding for Additive Manufacturing: An Equilibrium-Based Approach. SSNR. (2024). https://doi.org/10.2139/ssrn.5010635. [3] Ohlbrock, P.O., and D’Acunto, P. A Computer-Aided Approach to Equilibrium Design Based on Graphic Statics and C