Vol.:(0123456789) 1 3 Architecture, Structures and Construction https://doi.org/10.1007/s44150-022-00079-0 ORIGINAL PAPER Harnessing plastic deformation in porous 3D printed ceramic light screens James Clarke‑Hicks 1  · Isabel Ochoa 1  · David Correa 1 Received: 1 August 2022 / Accepted: 9 December 2022 © The Author(s), under exclusive licence to Springer Nature Switzerland AG 2022 Abstract Traditional fabrication methods of architectural ceramics seek to minimize plastic deformation during wet-processing by prioritizing sectional consistency. Adapting sectional thickness is critical for improving material performance to address localized functional requirements. Functionally Graded Additive Manufacturing (FGAM) enables a design-to-production process where sectional profles can be designed to achieve targeted performance characteristics. This research utilizes FGAM with Liquid Deposition Modelling (LDM) to prioritize sectional performance over form generation. Functionally graded 3D printed ceramic screens are produced for decorative lighting applications. Custom tool path generation is implemented to create modelling techniques that capitalize on the viscoelastic properties of clay. The prototypes obstruct, refect, and transmit light across their component sections to grade brightness and illumination. This paper outlines the methods involved in altering plastic deformation during the wet-processing of porous clay structures and the corresponding light-scattering behaviour of their ceramic counterparts. The light screens are organized by the resolution of porosity within each series of prototypes. In the 'Small' typology, deformation is utilized at the scale of a single print layer to form a dense multi-layered sectional condition that disperses light evenly. In the 'Medium' typology, deformation is compounded over multiple layers to form directional light apertures. In the 'Large' typology, extrusion variation is introduced to exaggerate deformation and generate multi-directional light scattering. Keywords Clay 3D printing · Liquid deposition modelling · Design to production workfow · Additive manufacturing · Material architectures · Hierarchical structures Introduction Architectural ceramics and additive manufacturing In contemporary architectural ceramic craft, formative approaches to fabrication aim to homogenize material attributes [1]. In industry, this homogeneity provides formal consistency across individual ceramic units, making pro- duction processes more predictable and cost-efective. In building construction applications, this consistency enables the integration of individual ceramic units into large, aggre- gate systems (e.g., bricks or tiles) [2]. Formative techniques for processing clay utilize moulds or formwork to minimize plastic deformation during wet-processing. This research deviates from the conventions of ceramic fabrication meth- odologies that encourage regularized performance attributes by minimizing deformation. This paper proposes a method- ology that utilizes the plastic deformation of clay and addi- tive manufacturing to create variable sectional conditions in ceramics not possible through alternative production processes [3]. The proposed methodology can integrate graded mate- rial performance into the wet-processing of ceramic com- ponents. Liquid Deposition Modelling (LDM) is a popular form of ceramic 3D printing due to its relatively low cost and utilization of common clay bodies [4]. LDM printing with clay does not typically employ support material, moulds, or formwork, diferentiating it from other methods of addi- tive manufacturing and ceramic production. LDM relies on This manuscript is to be considered for the special issue on "Intelligent Construction and Automation: Challenges and Emerging Technologies". * James Clarke-Hicks jclarkehicks@gmail.com 1 School of Architecture, University of Waterloo, Cambridge, Canada