3D Printing of Earth-Based Mixtures: Linking Material Design, Printability, and Structural Performance

The advancement of sustainable construction requires the development of earthen materials compatible with 3D printing (additive manufacturing), along with specified engineering standards. Many existing studies improve workability and early strength using chemical stabilizers such as cement; however, these additives increase embodied carbon and undermine sustainability objectives. Challenges remain in the formulation of an earthen mixture that satisfies both printability and structural requirements for large-scale construction. Previous earth-based mixes have reported excessive shrinkage and inadequate compressive strength. This study presents the systematic optimization of a low-carbon, 3D-printable earthen mixture using locally sourced clay-loam soil from Belén, New Mexico (NM). The soil was modified with graded concrete sand and rice hull fiber to improve printing parameters such as buildability, extrudability, and printability while meeting the NM Earthen Building Code requirements for compressive and flexural strength. Soil characterization tests (particle size distribution, consistency, optimal water content) guided iterative refinement to enhance dimensional stability and mechanical performance. A baseline 2:1 soil-to-sand ratio (max aggregate size No. 4) was established. Incorporating 2% rice hull fiber and reducing max aggregate size to No. 16 (S67F2) early-age shrinkage was reduced from 12.33% to 3.48% (72% reduction) while maintaining a 28-day compressive strength exceeding 660 psi, more than twice the code minimum. The optimized mixture supported 24 printed layers without deformation, achieved 189 psi flexural strength (three times the code minimum), and produced a stable 2-ft-diameter dome with minimal cracking.