Optimized Vault Structure

This research explores the application of an edge expansion algorithm to voussoir tessellation in the construction of structurally optimized, un-reinforced terra cotta masonry shell structures using 3D printing. By integrating additive manufacturing techniques with architectural clay materials, the study aims to enhance the structural stability and fabrication feasibility of thin masonry shells. The edge expansion algorithm, inspired by plant epidermal cells, increases the structure’s ability to withstand partial failures rather than experiencing immediate collapse. The methodology includes parametric modeling, genetic algorithms for form finding, structural analysis, and 3D printing. Results show improved interlocking of voussoirs, material efficiency, and reduced displacement, though challenges with dimensional accuracy due to clay viscosity were noted.