Exploring Multi-Directional 3D Printing for Enclosures on Earth and Beyond: Sensitivity Analysis of Buildability

Architecture in space demands innovative solutions to address the challenges of constructing robust, airtight habitats on extraterrestrial surfaces. Additive manufacturing (AM) has emerged as a promising technology for building habitats on celestial bodies, such as Mars, due to its adaptability and potential for automated construction. While 3D printing techniques on Earth have proven effective for building components, challenges persist in printing enclosures and the utilization of various mixed fabrication methods for roof construction. The study aims to lower the printable overhang angle, addressing restrictions posed by a 60-degree limit in horizontal or corbelling slicing techniques. Inspired by historical bricklaying, the research explores multidirectional printing with corbelling, radial, and inclined slicing techniques. The paper focuses on a sensitivity analysis study aimed at understanding the impact of geometric variables on the printability of barrel vaults using combined horizontal and inclined slicing techniques. A simulator of structural behavior during printing developed previously is used to predict the number of printed layers until collapse. Results suggest that it is possible to maintain the number of printable layers while lowering the overhang angle. While these results still need to be validated through printing experiments, they constitute a stepstone in the development of a design optimization tool to assist in the design of 3D printed enclosures.