Additive manufacturing earth-based composite: strategical and computational methodology for building shell geometries

Abstract

This paper explores shell geometry systems using additive manufacturing earth-based composite materials. These systems use continuous additive manufacturing methods based on logical similarities between the brick assembling process and extrusion layer path of self-supported geometries. The structural concept of shell systems will be illustrated by contemporary and historical case studies that have been developed to build self-supported cantilevers, vaults, and domes. Shell thin surfaces with overhangs will be tested by exploring the relationship between the geometry and the structural behavior through the 3D printing process. Structural properties will be assessed considering two main aspects: the shell structural integrity during the printing process, while the material is wet or uncured, and the printed-dried outcomes and loads. The mechanical performance parameters, which are balance, strength, local inertia, global inertia, and stiffness, will also be assessed physically and digitally. The design strategy of the shell wall development will be based on the infill design parameters that influence its work in summer and winter to improve thermal behavior, namely, the thermal transmission and radiation.