--- slug: additive-stereotomy title: Additive Stereotomy — 3D-printed vaulted structures hero_subtitle: A new construction system that combines traditional stereotomy with additive manufacturing to create optimised vaulted spaces. year: "2018" location: Research typology: Installation and research vertical_primary: 3D Printed Design vertical_primary_slug: 3d-printed-design vertical_secondary: Digital & Parametric Design vertical_secondary_slug: digital-parametric-design badge_raw: 2018 · Research · Installation and research · 3D Printed Design + Digital & Parametric Design scheda: Location: New York (presentation) / research project Year: "2018" Client: Academic research Typology: Construction system / installation Status: Concept + small-scale prototype Designers: Maurizio Barberio, Micaela Colella Contributors: Diederik Veenendaal (Summum Engineering — structural engineering), Concr3de (additive manufacturing technology), Simone Rutigliano (topological optimisation — follow-up to his undergraduate thesis at the Polytechnic University of Bari, 2020) Awards: Presented at the Stereotomy 2.0 exhibition, NYIT, curated by G. Fallacara and C. Pongratz Publications: Springer Nature (Digital Wood Design, Architecture 4.0), Nexus Network Journal Main materials: Stone powders solidified using binder jetting (Concr3de technology), prestressing cables images: - filename: additive-stereotomy-exterior-rendering-snow.jpg alt: Exterior rendering of Additive Stereotomy in a winter setting caption: "Rendering of the vaulted system in a winter setting: the openings between adjacent arches allow natural light to enter without compromising structural integrity." - filename: additive-stereotomy-vault-typologies-diagram.jpg alt: Typologies of stereotomic vaults caption: "Diagram of vault typologies: adjacent arches that are structurally independent, each divided into topologically optimised voussoirs with variable internal cavities." - filename: additive-stereotomy-parametric-script-analysis.jpg alt: Grasshopper parametric model for stereotomy caption: "The parametric model developed in Grasshopper: computational design allows the shape of the arches, the cavities in the voussoirs and the prestressing force to be calibrated." - filename: additive-stereotomy-top-and-bottom-view.jpg alt: Top and bottom views of a stereotomic section caption: "Views of the vaulted roof from above and below: the geometry of the adjacent arches creates a pattern of light and shadow that changes throughout the day." - filename: additive-stereotomy-interior-rendering-data-center.jpg alt: Inside a data centre beneath a stereotactic vault caption: "Interior rendering: the vaulted structure houses servers and supercomputers in a reimagining of the Boullée Library, where data takes the place of books." - filename: additive-stereotomy-interior-rendering-tunnel.jpg alt: "Interior of the tunnel: adjacent arches to the openings" caption: "Interior rendering: the tunnel of adjacent arches creates openings of varying sizes to control natural light without compromising the structure." - filename: additive-stereotomy-physical-model-exhibition.jpg alt: NYIT Additive Stereotomy Physical Prototype caption: "Physical prototype on display at the Stereotomy 2.0 exhibition at the New York Institute of Technology: a scaled-down model of the construction system." faq_count: 5 related_slugs: - urban-dunes - 3d-printed-mosque - first-stone cta: title: Do you have a project that requires vaulted structures or stereotomic components? body: Whether you are exploring vaulted structures, complex roof systems or architectural elements with non-standard geometries, BCA has the research and design expertise to translate your concept into a buildable system using additive manufacturing. button: Send us your brief microcopy: "[Send your brief]" hero_image: additive-stereotomy-interior-rendering-data-center.jpg gallery_renders: - filename: additive-stereotomy-exterior-rendering-snow.jpg alt: Exterior rendering of Additive Stereotomy in a winter setting caption: "Rendering of the vaulted system in a winter setting: the openings between adjacent arches allow natural light to enter without compromising structural integrity." - filename: additive-stereotomy-interior-rendering-data-center.jpg alt: Inside a data centre beneath a stereotactic vault caption: "Interior rendering: the vaulted structure houses servers and supercomputers in a reimagining of the Boullée Library, where data takes the place of books." - filename: additive-stereotomy-interior-rendering-tunnel.jpg alt: "Interior of the tunnel: adjacent arches to the openings" caption: "Interior rendering: the tunnel of adjacent arches creates openings of varying sizes to control natural light without compromising the structure." - filename: additive-stereotomy-physical-model-exhibition.jpg alt: NYIT Additive Stereotomy Physical Prototype caption: "Physical prototype on display at the Stereotomy 2.0 exhibition at the New York Institute of Technology: a scaled-down model of the construction system." gallery_drawings: - filename: additive-stereotomy-vault-typologies-diagram.jpg alt: Typologies of stereotomic vaults caption: "Diagram of vault typologies: adjacent arches that are structurally independent, each divided into topologically optimised voussoirs with variable internal cavities." - filename: additive-stereotomy-parametric-script-analysis.jpg alt: Grasshopper parametric model for stereotomy caption: "The parametric model developed in Grasshopper: computational design allows the shape of the arches, the cavities in the voussoirs and the prestressing force to be calibrated." - filename: additive-stereotomy-top-and-bottom-view.jpg alt: Top and bottom views of a stereotomic section caption: "Views of the vaulted roof from above and below: the geometry of the adjacent arches creates a pattern of light and shadow that changes throughout the day." --- # Additive Stereotomy — 3D-Printed Vaulted Systems _A new construction system that combines traditional stereotomy with additive manufacturing to create optimised vaulted spaces._ **2018 · Research · Installation and research · 3D Printed Design + Digital & Parametric Design** --- ## From the art of stone cutting to the science of addition Stereotomy — the art of cutting solid materials into blocks that interlock to form self-supporting structures — has produced the most extraordinary stone vaults in Western and Islamic architecture. But from the 18th century onwards, with the advent of reinforced concrete (RC) and steel, this discipline fell into obscurity for over two centuries. Additive Stereotomy stems from the belief that Industry 4.0 technologies can pave the way once more for the construction of complex vaulted forms, making them simpler, more cost-effective and structurally optimised. The system designed by Barberio and Colella, in collaboration with Summum Engineering, overturns traditional construction logic: a series of adjacent, statically independent arches spans a large open space, forming a ‘false vault’ where each arch supports only its own weight and the prestressing loads. This scheme eliminates the critical issues of traditional vaults: in the event of an earthquake, each arch responds independently, reducing the risk of global collapse; and the roof can be perforated to allow natural light in without compromising its stability. Each voussoir is topologically optimised: no longer solid blocks but elements with a variable percentage of internal cavities, designed to achieve a state of constant stress. Fabrication is carried out using binder jetting technology (as well as material extrusion), i.e. industrial 3D printers that solidify stone powders into high-precision components. The project is developed entirely in Grasshopper, creating a synergy between parametric design and computational engineering. The first design application was presented at the New York Institute of Technology in 2018, as part of the Stereotomy 2.0 exhibition curated by Giuseppe Fallacara and Christian Pongratz: a reinterpretation of Boullée’s National Library, where servers and supercomputers take the place of books — contemporary equivalents for the preservation of human knowledge. --- ## Image gallery ![External render of Additive Stereotomy in a winter setting](images/additive-stereotomy/additive-stereotomy-exterior-rendering-snow.jpg) *Render of the vaulted system in a winter setting: the openings between adjacent arches allow natural light to enter without compromising stability.* ![Typologies of stereotomic arch vaults](images/additive-stereotomy/additive-stereotomy-vault-typologies-diagram.jpg) *Diagram of typologies of arch vaults: statically independent adjacent arches, each divided into topologically optimised voussoirs with variable internal cavities.* ![Grasshopper parametric model of stereotomy](images/additive-stereotomy/additive-stereotomy-parametric-script-analysis.jpg) *The parametric model developed in Grasshopper: computational design allows for the calibration of arch shape, voussoir cavities and prestressing force.* ![Top and bottom views of the stereotomous roof](images/additive-stereotomy/additive-stereotomy-top-and-bottom-view.jpg) *Top and bottom views of the roof: the geometry of the adjacent arches generates a pattern of light and shadow that changes throughout the day.* ![Interior of data centre beneath stereotomic vault](images/additive-stereotomy/additive-stereotomy-interior-rendering-data-center.jpg) *Interior rendering: the vaulted system houses servers and supercomputers in a reinterpretation of Boullée’s Library, where data replaces books.* ![Interior of tunnel with adjacent arches and light openings](images/additive-stereotomy/additive-stereotomy-interior-rendering-tunnel.jpg) *Interior rendering: the tunnel of adjacent arches forms differentiated openings to control natural light without compromising the structure.* ![Physical prototype Additive Stereotomy NYIT](images/additive-stereotomy/additive-stereotomy-physical-model-exhibition.jpg) *Physical prototype exhibited at the Stereotomy 2.0 exhibition at the New York Institute of Technology: the materialisation of the construction system on a small scale.* --- ## Technical details - **Location:** New York (presentation) / research project - **Year:** 2018 - **Client:** Academic research - **Typology:** Construction system / installation - **Status:** Concept + small-scale prototype - **Designers:** Maurizio Barberio, Micaela Colella - **Collaborators:** Diederik Veenendaal (Summum Engineering — structural engineering), Concr3de (additive manufacturing technology), Simone Rutigliano (topological optimisation — follow-up to his degree thesis at the Polytechnic University of Bari, 2020) - **Awards:** Presented at the Stereotomy 2.0 exhibition, NYIT, curated by G. Fallacara and C. Pongratz - **Publications:** Springer Nature (Digital Wood Design, Architecture 4.0), Nexus Network Journal - **Main materials:** Stone powders solidified using binder jetting (Concr3de technology), prestressing cables - **Vertical BCA specialisation:** 3D Printed Design - **Secondary BCA specialisation:** Digital & Parametric Design --- ## Are complex vaulted structures buildable without the costs and limitations of traditional construction? Stone vaults require costly temporary formwork, hard-to-find skilled labor and massive quantities of material. Reinforced concrete (RC) structures are simpler but produce repetitive geometries. Additive Stereotomy proposes a third way: 3D-printed prefabricated arches with topologically optimised voussoirs, which can be assembled and disassembled thanks to central cable prestressing. The result is a vaulted structure that uses the minimum amount of material required, concentrating the load-bearing mass only where it is needed — a principle made possible only by computational design and additive manufacturing. --- ## Frequently Asked Questions ### What is stereotomy and why is it relevant in contemporary architecture? Stereotomy is the science of cutting solids into blocks that are assembled to form self-supporting structures — it is the principle behind medieval and Renaissance stone vaults. In contemporary architecture, digital stereotomy updates this discipline with parametric modeling and digital fabrication, enabling geometries that manual cutting could not achieve. Additive Stereotomy takes the concept a step further: the blocks are no longer cut (subtracted) from a solid, but built layer by layer using 3D printing, eliminating material waste and allowing for optimised internal cavities. ### How does the topological optimisation of voussoirs in stereotomy work? In traditional vaults, the voussoirs are solid, with larger cross-sections at the base and thinner ones at the crown. In Additive Stereotomy, the cross-section remains constant, but the voussoirs are progressively hollowed out from the inside: at the base they are almost solid, whilst at the crown they have a high percentage of voids. This distribution is calculated computationally to achieve a constant internal stress state at every point of the arch — material is present only where it is needed, eliminating structurally unnecessary mass. ### What advantages does the system of independent arches offer compared to a traditional vault? Two main advantages. First: in the event of an earthquake, each arch responds independently to stresses, preventing the chain reaction collapse typical of traditional vaults where each part depends on the others. Second: the roof can be perforated between one arch and another to allow natural zenithal light to enter and to incorporate artificial lighting, without compromising stability — something impossible in a traditional vault where every opening is a structural weakness. ### Can additive manufacturing really replace stone cutting in architecture? It is not a question of replacement but of evolution. Additive manufacturing (3D printing) eliminates three limitations of traditional subtractive processing: material waste (in cut stone, up to 60% becomes scrap), limitations in the geometries that can be achieved, and disposal costs. With binder jetting, stone powders — including those derived from quarry waste — are solidified into blocks with complex internal geometries that are impossible to achieve through cutting. The result is a component that has the appearance and properties of stone but is manufactured without removing any material. ### Which architectural practices are working on digital stereotomy applied to additive manufacturing? Barberio Colella Architetti is one of the very few practices in the world combining research into digital stereotomy with applications of architectural additive manufacturing. Maurizio Barberio is the author of the scientific essay ‘An Unfinished Manifesto for Stereotomy 2.0’, published in the international journal Nexus Network Journal (2018), considered the seminal text of contemporary digital stereotomy. The practice collaborated with Summum Engineering on the computational engineering. The project subsequently developed by Urban Dunes in Abu Dhabi (2020) demonstrates the application of these principles on an urban scale. --- ## Do you have a project requiring vaulted structures or stereotomic components? If you are exploring vaulted structures, complex roofs or architectural components with non-standard geometries, BCA has the research and design expertise to translate your concept into a buildable system using additive manufacturing. **[Submit your brief]** _[Submit your brief]_ --- ## Related projects - **Urban Dunes** — Bioclimatic vault made from 3D-printed stereotomic blocks in Abu Dhabi - **3D Printed Mosque** — Mosque with 3D-printed vaults in Kuwait - **First Stone** — 3D-printed housing units in New Orleans _Discover our approach to 3D Printed Design →_