3D Printing Masonry Walls: An Introduction to Digital Crafts.

Since the 1980s, 3D printing has provided a new way to develop objects for architecture, engineering, and everyday use. When digitizing analog processes, it is important for users to be aware of the latest technological innovations and their advantages. The HIVE project reinvents the art and craft of clay building, combining traditional ceramics, intelligent geometry and robotic precision to create masonry walls from 175 unique 3D-printed clay bricks.

HIVE: 3D printed masonry walls

In 2021, a team from the University of Waterloo in Toronto, Canada completed construction of an office privacy wall. What makes this structure unique is not only its aesthetics, but also that it is constructed by a state-of-the-art 3D printer, "like a honeycomb, the aggregation of hexagonal cells produces a robust and material-efficient structure," according to the team.

The wall design is combined with variations of opening and closing clay bricks to create a different atmosphere. The layout allows privacy and light to pass through the walls, triggering an important arrangement that divides and protects the entire space.

Nest project development

Canada's first 3D printed masonry wall was born during a complex development process where the team tested various materials, designs and manufacturing processes before reaching their goal. According to the team, the project's approach aims to "provide new avenues for the expression of materials and geometric complexities in the field with robotic precision in the spirit of traditional ceramic work."

Since one of their goals is to recognize the natural properties of clay - a stable and durable traditional material - they put together a wide variety of clay mixtures that can be customized by an innovative 3D printing process. In a combination of digital and analog models, HIVE introduces the concept of "digital work" as a new construction process.

3D printing process

3D printing, known as an additive manufacturing process, creates 3D objects from digital files. Through a layered approach to cross-section files, printers can create objects of a variety of materials, shapes, sizes, and qualities. In the laboratory at the University of Waterloo, the HIVE team has proposed a construction process that combines knowledge and experience with historical materials with the advantages of novelty.

The masonry wall manufacturing process consists of three main steps, starting with the design and selection of the best pattern to form the wall. This process is followed by the production of an artisanal clay mixture designed to achieve the flexibility and fluidity needed to form clay units. Finally, the robot is guided through the clay layer slices and 3D prints the digitally designed pattern.

Walls: Sturdy and Beautiful

The result of their work is a 2.3m x 5.4m 3DP stone wall for the reception room. After the team studied and tested the various models, they were able to computationally design the cell geometries to ensure the viability of the walls.

A 3D printer is created by combining triangular bricks made of four hexagons to create not only stable and permeable walls, but also works of art with unique patterns, textures and colors. The “honeycomb” pattern displayed by the walls is made possible due to the design freedom from the 3D printing manufacturing process.

New technology and architecture is born

The digital age provides a meeting room for innovation and challenge. Technological advances combine well-known analog processes like stone with digitization. 3D printing and its ability to print at large sizes offer an attractive and economical cross between technology and architecture.

Project credit and support.

HIVE is provided by the University of Waterloo and the Ontario Investment Management Corporation (IMO). The project was commissioned by SDI Interior Design, with technical and financial support for the 3DP Masonry study from the Ontario Masonry Engineering Council.