Project Summary: 

Construction causes a lot of harm to the environment, so the industry now needs to cut that impact fast. Doing this means rethinking the materials we use, how we shape them, and how we build with them. On the fabrication side, digital tools and automation offer a real chance to build more efficiently. But using more digital technology in architecture brings new problems too, especially around whether sustainable materials work well with automated building processes. 

One promising material type is biocomposites. These are eco-friendly materials where natural fibres are mixed into a base material to give it strength. They break down naturally, cost little, need very little energy to produce, and are gentle on the environment. Earth is a great base material for these composites because it is cheap, easy to process, widely available, and can be reused. 

This study looks at earth-based composites as a sustainable option for automated construction. It looks at how to source and process earth locally, and how to improve its mechanical and structural strength so it can be used to build complex, freeform architectural shapes. To do this, the study builds and improves automated construction tools. This includes an adaptive mould system, compression and mechanical testing, optimizing the mix design, and running robotic fabrication tests. 

The research starts by studying earth as a material, since its properties are what should guide the design of the mould system. Traditional earth building methods like cob and adobe already allow freeform shapes when done by hand, but they fall short on accuracy and speed compared to mould-based digital fabrication. This research fills that gap by creating an adaptive mould that can accurately produce freeform earthen panels, shaped directly by how fibrous earth mixes behave. Before the mould can be properly designed, it’s important to first understand the material’s density, fibre content, and stiffness. 

Image: Research gap and direction diagram mapping the relationship between prevailing industry challenges and the proposed study response 

Image: Locally sourced earth, processed through digital fabrication, retains its recyclability and reusability throughout the material lifecycle