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As the field of 3D printing technologies expand, complex materials that require a deeper engagement, due to their more unstable properties, are of increasing interest. Cementitious composites, clays and other ceramic materials are of particular relevance: their potential for fast large-scale fabrication and local availability position these technologies at the forefront of expansion for 3D printing. Despite the extensive benefits inherent to clays, their irregularities and the largely unpredictable deviations that occur when printing from a digital model, currently limit design and architectural-scale applications. However, these deformations could conversely be harnessed as design generators, opening up avenues for both aesthetic and functional exploration. The paper presents an investigation into the inherent material instabilities of the clay 3D printing process for the development of an architectural masonry facade system. Through an iterative process based in craft, a new capacity for material expression and authenticity beyond previous manufacturing capabilities can become actualized.

Guiding Instability A craft-based approach for modular 3D clay printed masonry screen units