Programmable Mud: 3D Printing earth to achieve low-carbon, low-cost construction automation

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.

Name thesis:degree_name

Doctoral

Department dc:contributor.department

Massachusetts Institute of Technology. Department of Architecture

Grantor dc:publisher

Massachusetts Institute of Technology

Year dc:date.issued

2025

Author dc:creator

• Curth, Alexander (Sandy) McCormick

Advisor dc:contributor.advisor

• Sass, Lawrence

Statement dc:rights

• In Copyright - Educational Use Permitted
• Copyright retained by author(s)

Licence dc:rights.uri

• https://rightsstatements.org/page/InC-EDU/1.0/

Handle dc:identifier.uri

https://hdl.handle.net/1721.1/163545

OAI identifier oai:identifier

oai:dspace.mit.edu:1721.1/163545