Monolithic Earthen Shells Digital Fabrication: Hybrid Workflow

The digital fabrication process of monolithic shell structures is presenting some challenges related to the interface between computational design and fabrication techniques, such as the translation from the digital to the physical when a definite materiality appears during the final phase of the fabrication process, which is typically approached as a linear and predetermined sequence, most often not allowing any kind of adjustments or rectifications. This stage proves to be critical for monolithic shells, because their integrity relies on the continuity of the construction phases for its stability and durability. This paper exposes the implementation process required for new computational and physical methods for monolithic shells construction using digital fabrication techniques combined with skilled/non-monotonous manual craft. It proposes an additive manufacturing deposition process for paste clay mixes with the potential of embedding a certain level of interactivity between the fabricator and the materialized model during the fabrication process, to allow for real time adjustments or corrections. Two case studies are featured, detailing the steps required to take advantage of the flow involving manual craft, digital modeling, and digital fabrication tools. These methods aim at renewing shells construction processes, in terms of the time it takes to build them, the optimization of materials and labor, and the feasibility of the dweller to be involved during different construction phases