Graphic Statics-Based Form-Finding of Layer-Wise Self-Supporting Vaulted Structures Fabricated using Robotic Extrusion 3D Printing

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

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Rooted in the principles of graphic statics [1], this work presents a fabrication-aware form-finding method for generating print layer-wise self-supporting compression-dominant vaulted structures using robotic extrusion 3D printing. Drawing inspiration from historical masonry construction techniques, the research reinterprets these principles using contemporary computational design and digital fabrication methodologies. The proposed method simultaneously determines the final geometric configuration and the print path through an iterative, layer-wise process, maintaining compression-dominated internal force transmission during fabrication. The approach is based on Combinatorial Equilibrium Modelling (CEM) [2], enabling the iterative control of internal normal force distributions layer by layer, considering one closed layer per iteration. Structural, material, and fabrication constraints are directly embedded into the design workflow at both the final and individual layer-wise states, strategically constraining the design space to enable feasible, continuous, and formwork-free robotic fabrication using materials with high compressive strength and comparatively low tensile capacity, such as concrete or earth. The design method is validated through a series of design studies and small-scale prototypes fabricated using earthen materials [3] and cementitious mortar [4]. These prototypes demonstrate the feasibility and structural integrity of the resulting vaulted structures, highlighting the potential of this interdisciplinary approach to bridge historical construction principles with contemporary structural form-finding and digital fabrication techniques. REFERENCES [1] D’Acunto, P., Jasienski, J.-P., Ohlbrock, P.O., Fivet, C., Schwartz, J., and Zastavni, D. Vector-based 3D graphic statics: a framework for the design of spatial structures based on the relation between form and forces. International Journal of Solids and Structures 167. https://doi.org/10.1016/j.ijsolstr.2019.02.008. (2019) [2] Ohlbrock, P.O., and D’Acunto, P. A Computer-Aided Approach to Equilibrium Design Based on Graphic Statics and Combinatorial Variations. Computer-Aided Design 121. (2020). https://doi.org/10.1016/j.cad.2019.102802. [3] 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). [4] Chovghi, F., Richter,