The nesting brick an AM ceramics case study

The production of ceramic bricks is a high-yield process, creating hundreds of units per hour. The common process for this is restricted in terms of geometry. Complex shaped ceramic pieces often require extensive efforts in production, such as manual labor, which drives up costs. Additive Manufacturing methodologies promise to ease the production of bespoke parts and small series in general. Robocasting is perceived as suitable to 3D-print large ceramic components for architectural applications. This case study investigates the usability of Robocasting for architectural applications by reproducing a market-proven custom component. Besides proposing a digitally driven workflow for the creation of it, emphasis was placed on using a clay mixture that blends well into common brick systems. The performed research proved that Robocasting is a viable alternative to prevalent production methods for bespoke ceramic building components. By transitioning a manual process, further automation in the construction industry is promoted.