Additive Manufacturing with Clay and Ceramics: Materials, Modeling, and Applications

Additive manufacturing (AM) with clay and ceramic-based materials is gaining momentum as a sustainable alternative in construction, yet its advancement depends on bridging experimental practice with predictive modeling. This review synthesizes advances in mathematical formulations and numerical tools applied to clay, geopolymers, alumina, and related extrusion-based pastes. Classical rheological models, including the Bingham and Herschel–Bulkley formulations, remain central for characterizing yield stress, structuration, and flow stability. Meanwhile, finite element (FEM) and computational fluid dynamics (CFD) approaches are increasingly supporting predictions of deformation, shrinkage, drying, and sintering. Despite these advances, their application to natural clay systems remains limited due to heterogeneity, moisture sensitivity, and the lack of standardized constitutive parameters. Recent studies emphasize that validation is essential: rheometry, layer stability tests, in situ monitoring, and prototyping provide necessary calibration for reliable simulation. In parallel, parametric and generative design workflows, particularly through Rhino and Grasshopper ecosystems, illustrate how digital methods can link geometric logic, fabrication constraints, and performance criteria. Overall, the literature demonstrates a transition from isolated modeling efforts toward integrated, iterative frameworks where rheology, numerical simulation, and experimental validation converge to improve predictability, reduce trial-and-error, and advance scalable and sustainable clay- and ceramic-based AM.