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<p>This paper introduces Earth Form—an explorative study for a regenerative casting method that employs scored, fluid clay as temporary and circular formwork for concrete structures. Unlike precision-based digital formwork systems that rely on energy-intensive 3D-printing of polymerous or cementitious mixtures with limited circularity, Earth Form explores how natural crack propagation in reusable earthen slurries can be initiated and guided using minimal robotic scoring to mitigate typical energy outputs. After production, the earthen formwork is demolded via water soaking, closing the production loop. This study investigates how such a process can be steered toward reproducible, structurally relevant geometries. Three sets of experiments were designed: calibration, small-scale, and medium-scale tests; establishing preliminary benchmarks in terms of fabrication feasibility, such as degree of control and tolerance, drying time, and energy consumption. An early scoped Life Cycle Assessment is consequently presented comparing extrapolated ranges with equivalent formworks using 3d printed earth and polymers. While not yet structurally validated, this study demonstrates foundational principles for further research into material-responsive architectural systems using a low-energy and low-intervention approach for earthen formworks and mixtures.</p>

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Self-shaping clay formworks: an exploratory study on controlling time-based cracking in robotically scored clay slurries

  • 期刊论文

  • 发表日期：

    2026年4月29日

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  • Sacha Cutajar,
  • Vanessa Calderon,
  • Ena Lloret-Fritschi

摘要

This paper introduces Earth Form—an explorative study for a regenerative casting method that employs scored, fluid clay as temporary and circular formwork for concrete structures. Unlike precision-based digital formwork systems that rely on energy-intensive 3D-printing of polymerous or cementitious mixtures with limited circularity, Earth Form explores how natural crack propagation in reusable earthen slurries can be initiated and guided using minimal robotic scoring to mitigate typical energy outputs. After production, the earthen formwork is demolded via water soaking, closing the production loop. This study investigates how such a process can be steered toward reproducible, structurally relevant geometries. Three sets of experiments were designed: calibration, small-scale, and medium-scale tests; establishing preliminary benchmarks in terms of fabrication feasibility, such as degree of control and tolerance, drying time, and energy consumption. An early scoped Life Cycle Assessment is consequently presented comparing extrapolated ranges with equivalent formworks using 3d printed earth and polymers. While not yet structurally validated, this study demonstrates foundational principles for further research into material-responsive architectural systems using a low-energy and low-intervention approach for earthen formworks and mixtures.