Structural Stability of 3D-Printed Earthen Catenary Domes (2025-09)¶

3D printing technology has been increasingly growing in the construction sector to overcome the limitations of complex structures with various innovative materials. Nowadays, earthen-based materials have gained considerable attention, primarily due to their ecological sustainability; however, their structural stability and low tensile strength pose a significant challenge in construction and building design considerations. This paper investigates the structural stability and compressive strength of self-supporting 3D printed earthen-based domes, with a focus on evaluating the influence of rib reinforcements on enhancing their load-bearing capacity and overall performance. The experimental approach began with an assessment of earthen materials suitable for 3D printing, identifying challenges and potential failures associated with these materials, followed by physical testing. The methodology in this study was divided into four main phases; 1) material testing phase to determine an optimal mix for 3D printing, 2) digital design phase, to create catenary domes with various ribs configurations, 3) fabrication phase, involving 3D printing of the prototypes with earth-based materials, and 4) mechanical testing to evaluate the structural performance of the printed domes. Key printing parameters influencing structural stability, such as; rib geometry, cantilever inclination, and material behaviour-were carefully considered. Findings demonstrated that increasing the number of ribs can significantly enhance the compressive stress of the dome’s structure by up to 52 % compared to a standard catenary dome, advancing the development of sustainable, digitally fabricated architectural solutions utilizing earthen materials.