Led by architects Ronald Rael and Virginia San Fratello, design studio Rael San Fratello has become well-known for creating innovative and sustainable designs, but now the studio is truly breaking ground when it comes to 3D printing. As part of its Emerging Objects series, the design team has created four solid mud structures. Built by a low-cost, portable 3D robot, the four buildings were all printed using soil and wood sourced on site in Colorado’s expansive Valle de San Luis.

rounded structure made of mud and sticks

rounded structure made of mud and stick

The team chose Colorado’s San Luis Valley as the site for their series due to its rich history of Ancestral Pueblo and the Indo-Hispano cultures. Referring to the traditional building practices of these cultures, which predominately included using earthen materials to create sturdy housing, Rael San Fratello has managed to create four 3D-printed prototypes: Hearth, Beacon, Lookout and Kiln, that explore the various techniques of mud construction.

3d printer printing large coils of mud

3d printer printing large coils of mud

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The project, called Mud Frontiers, began by researching the typical earthen items that have been made from the clay harvested from the area. They then collaborated with 3D ceramic print company 3D Potter to create a small, portable robot called Potterbot XLS-1, which was built to print the mud creations on site.

3d printer printing large coils of mud

rounded structure made of mud and stick

The first design, Hearth was built using a thin wall of mud reinforced with rot-resistant juniper wood. This structure has a tiny fireplace on the interior that burns the wood as well.

rounded structure made of mud and stick

woman standing on rounded structure made of mud and stick

The second design, Beacon was designed to research just how thin the mud walls could be by stacking various coils of mudwork. In this structure, light illuminates through the indentations along the walls, serving as a “beacon” of light.

rounded structure made of mud and stick with a fire on the inside

rounded structure made of mud and stick with a fire on the inside

The third design, Lookout, was comprised of a network of undulating mud coils that are layers to form a staircase, creating a structure that is strong enough to withstand substantial weight. Additionally, this structure was built with cross sections of mud piping that can be used to create a system of natural air circulation through various openings.

rounded structure made of mud and stick

rounded structure made of mud and stick

The final prototype, Kiln, included a culmination of the anterior designs, but adds a kiln that uses locally-sourced clay fired with juniper wood to create earthen ware items.

rounded structure made of mud and stick

Using the various traditional techniques helped designers determine that mud could indeed be a viable solution for providing more affordable construction options in the future. Especially as urban and rural area designers and architects look for sustainable materials to build resilient structures.

3d printer printing large coils of mud

“What we learned was really how accessible, robust and powerful it was to print large scale structures so quickly using the soil just beneath our feet,” Rael told Dezeen. “We discovered work flows for printing, material mixture processes, structural applications and theories about new and old ways of living and designing for the future using humankind’s most humble material.”

+ Rael San Fratello

+ Emerging Objects

Via Dezeen

Photography by Rael San Fratello