Fabricating lightweight ceramics by spraying clay on knitted structures

Lukas Gosch*, Julian Jauk, Hana Vasatko, Elizabeta Šamec, Matteo Raffaelli, Stefan Rutzinger, Milena Stavric

*Corresponding author for this work

Research output: Contribution to journalConference articlepeer-review

Abstract

This research was carried out to develop a novel composite material consisting of a thread reinforcement and a clay matrix, as well as to develop a method of shaping this material into hollow spatial structures. Ceramic elements in the building industry are currently created by applying extruding, pressing and casting methods. The approach of spraying clay onto predefined knitted meshes increases the usability of digitally fabricated lightweight ceramic elements, while eliminating the need for scaffolding. In this approach, multiple layers of a fluid clay mass are sprayed onto the tensioned mesh using an industrial, six-axis robotic arm. This allows the precise application of the material and results in varying material thicknesses. Due to the complementary qualities of clay which absorbs compressive forces and threads which absorb tensile forces, lightweight structures can be created. The research involved experimenting with clay mixtures, several thread types, knitting methods and spraying techniques, as well as fabricating a 1:1 lightweight module as an architectural prototype.
Original languageEnglish
Pages (from-to)693-706
Number of pages14
JournalInternational Journal of Architectural Computing
Volume20
Issue number4
Early online date18 Oct 2022
DOIs
Publication statusPublished - Dec 2022
Event40th Conference on Education and Research in Computer Aided Architectural Design in Europe: eCAADe 2022 - Ghent, Belgium
Duration: 13 Sept 202216 Sept 2022

Keywords

  • ceramics
  • digital fabrication
  • knitted threads
  • mesh formwork
  • six-axis robotic arm
  • spraying

ASJC Scopus subject areas

  • Building and Construction
  • Computer Science Applications
  • Computer Graphics and Computer-Aided Design

Fields of Expertise

  • Advanced Materials Science

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