Coextrusion of Clay-Based Composites: Using a Multi-Material Approach to Achieve Gradient Porosity in 3D-Printed Ceramics

Abstract

3D printing of ceramics has started gaining traction in architecture over the past decades. However, many existing paste-based extrusion techniques have not yet been adapted or made feasible in ceramics. A notable example is coextrusion, a common approach to extruding multiple materials simultaneously when 3D-printing thermoplastics or concrete. In this study, coextrusion was utilized to enable multi-material 3D printing of ceramic elements, aiming to achieve functionally graded porosities at an architectural scale. The research presented in this paper was carried out in two consecutive phases: (1) The development of hardware components, such as distinct material mixtures and a dual extruder setup including a custom nozzle, along with software environments suitable for printing gradient materials. (2) Material experiments including material testing and the production of exemplary prototypes. Among the various potential applications discussed, the developed coextrusion method for clay-based composites was utilized to fabricate ceramic objects with varying material properties. This was achieved by introducing a combustible as a variable additive while printing, resulting in a gradient porosity in the object after firing. The research’s originality can be summarized as the development of clay-based material mixtures encompassing porosity agents for 3D printing, along with comprehensive material-specific printing parameter settings for various compositions, which collectively enable the successful creation of functionally graded architectural building elements. These studies are expected to broaden the scope of 3D-printed clay in architecture, as it allows for performance optimization in terms of structural performance, insulation, humidity regulation, water absorption and acoustics.