2026-09-19T10:08:15Zhttps://dspace.mit.edu/server/oai/requestoai:dspace.mit.edu:1721.1/1635452025-11-06T03:04:33Zcom_1721.1_7582com_1721.1_7581col_1721.1_131022
Sass, Lawrence
Curth, Alexander (Sandy) McCormick
Massachusetts Institute of Technology. Department of Architecture
2025-11-05T19:33:37Z
2025-11-05T19:33:37Z
2025-05
2025-08-12T18:48:02.528Z
https://hdl.handle.net/1721.1/163545
https://orcid.org/0000-0002-3902-1787
Large-scale additive manufacturing (LSAM) with locally sourced materials, such as earth, presents a promising approach to addressing the urgent challenges of rapid urbanization and construction-related carbon emissions.
This dissertation establishes a comprehensive framework for integrating low-carbon materials, particularly minimally processed earth, with computational design methodologies and robotic fabrication processes for architectural-scale applications. Through systematic material characterization, novel testing protocols, and case studies across multiple building systems, the research demonstrates that minimally processed earthen materials can be transformed into high-performance building elements uniquely suited to local environmental conditions and design considerations. The developed computational framework employs multi-objective optimization and material-aware toolpath generation to balance structural performance, thermal comfort, embodied carbon, and construction time.
Four case studies validate this approach: (1) toolpath optimization for shell structures, (2) a hybrid floor system combining shape-optimized concrete beams with 3D-printed ceramic blocks, (3) zero-waste earthen formwork for reinforced concrete, and (4) thermally optimized wall systems for passive climate control. Life cycle assessment reveals that 3D-printed earth structures have approximately one-fifth the embodied carbon of conventional concrete and one-fiftieth that of industry-standard 3D-printed mortar. This research bridges the gap between additive computational design and material circularity, offering scalable approaches to sustainable construction that can be implemented across diverse environmental and economic contexts.
Ph.D.
Massachusetts Institute of Technology
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Copyright retained by author(s)
https://rightsstatements.org/page/InC-EDU/1.0/
Programmable Mud: 3D Printing earth to achieve low-carbon, low-cost construction automation
Thesis
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Doctoral
Doctor of Philosophy
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<Abstract>Large-scale additive manufacturing (LSAM) with locally sourced materials, such as earth, presents a promising approach to addressing the urgent challenges of rapid urbanization and construction-related carbon emissions.
This dissertation establishes a comprehensive framework for integrating low-carbon materials, particularly minimally processed earth, with computational design methodologies and robotic fabrication processes for architectural-scale applications. Through systematic material characterization, novel testing protocols, and case studies across multiple building systems, the research demonstrates that minimally processed earthen materials can be transformed into high-performance building elements uniquely suited to local environmental conditions and design considerations. The developed computational framework employs multi-objective optimization and material-aware toolpath generation to balance structural performance, thermal comfort, embodied carbon, and construction time.
Four case studies validate this approach: (1) toolpath optimization for shell structures, (2) a hybrid floor system combining shape-optimized concrete beams with 3D-printed ceramic blocks, (3) zero-waste earthen formwork for reinforced concrete, and (4) thermally optimized wall systems for passive climate control. Life cycle assessment reveals that 3D-printed earth structures have approximately one-fifth the embodied carbon of conventional concrete and one-fiftieth that of industry-standard 3D-printed mortar. This research bridges the gap between additive computational design and material circularity, offering scalable approaches to sustainable construction that can be implemented across diverse environmental and economic contexts.</Abstract>
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