Project Summary: 

The construction sector significantly contributes to global waste and greenhouse gas emissions. Two major areas in construction impact the environment: the materials used and the fabrication processes. Many building materials, such as concrete, steel, and plastics, are non-biodegradable and difficult to recycle or compost. Moreover, creating specialized architectural components often involves custom moulds that can only be used once. To address these challenges, this research focuses on two main approaches: decarbonization through renewable, low-impact materials and digitalization by utilising technologies like 3D printing for more efficient production. 

Earth is the focus of this study because it is abundant and can be sourced locally, making it particularly suitable for construction in remote areas with limited transportation options. The study investigates earth combined with hemp, mycelium, and spinifex fibers, which can enhance the strength, durability, and environmental benefits of 3D-printed earth structures. A key innovation in this research is the use of adjustable moulds with 3D printing. Unlike traditional moulds that are single-use, an adjustable mould can be modified to create various shapes, reducing waste, lowering costs, and increasing design flexibility. 

The study is organized into three stages: exploring materials, designing and fabricating, and evaluating performance. The first stage identifies optimal mixtures of earth and bio-fibers for strength and printability. These findings inform the fabrication stage, where adjustable moulds are used to create unique 3D-printed components. The final stage tests these components for structural integrity, environmental impact, and scalability. 

By integrating earth-based bio-mixtures with modern fabrication techniques, this research aims to advance both academic knowledge and industry practices. It demonstrates how traditional, locally sourced materials can work alongside advanced tools to reduce costs and environmental impact, increase precision, and enhance design options. This approach links sustainable building methods with contemporary construction technology, paving the way for more efficient and environmentally friendly construction. 

Image: 3D printing earth is a fundamentally circular building process 

Image: 3D printing earth-based biopanels using an adjustable mould