Learning From Leaves: A Bio-Informed Masonry Shell Structure Optimization Process

Additive manufacturing has enabled the fabrication of structurally optimized complex morphologies that were previously beyond conventional manufacturing capabilities. In the cases of thin masonry shell structures, structural optimizations were mainly in form-finding, cross-sectional variance and voussoir tessellation. These optimizations and tectonic considerations address structural stability, fabrication, and resource efficiency. This study aims to address the same criteria with the new capabilities of additive manufacturing using clay bodies as a building material. In addition, the study attempts to address unexpected point-loading scenarios that can result in the immediate collapse of unreinforced masonry structures. An edge expansion algorithm, similar to the cell wall morphology of epidermal cells in plant leaves, was designed and applied to voussoir tessellation to achieve edge interlocking behaviour, resulting in single-layer, lightweight brick vault with no binder or scaffolding due to improved distribution of stress.