--- slug: aetherius title: AETHERIUS — A modular pavilion 3D-printed using recycled concrete aggregates (RCA) hero_subtitle: An organic structure in which additive manufacturing transforms waste from the stone industry into architecture for the city. year: "2024" location: Apulia typology: Pavilion vertical_primary: 3D Printed Design vertical_primary_slug: 3d-printed-design badge_raw: 2024 · Puglia · Pavilion · 3D Printed Design scheda: Year: "2024" Client: B&Y Ltd (in collaboration with) Typology: Modular pavilion Status: Concept Designers: Maurizio Barberio, Micaela Colella (Barberio Colella Architects) Contributors: B&Y Ltd Main materials: 3D-printed mortar made from marble dust, stone and recycled concrete aggregates (RCA) images: - filename: aetherius-physical-model-chair.jpg alt: "AETHERIUS physical model: structural detail" caption: "Physical model of the pavilion: this section shows the internal geometry and the arrangement of the openings." - filename: aetherius-exhibition-model-full-view.jpg alt: Detail of the 3D-printed underside texture caption: The three-dimensional texture of the soffit, created by extrusion printing, is modular in its modulation of light and acoustics in interior spaces - filename: aetherius-exterior-rendering-day.jpg alt: Daytime rendering of AETHERIUS in a natural setting caption: "Daytime rendering: the pavilion blends seamlessly into its surroundings, with its organic form interacting with the surrounding landscape." - filename: aetherius-exterior-rendering-day-seafront.jpg alt: 3D-printed module made from recycled concrete aggregates (RCA) mortar caption: Detail of the structural module extruded from a mortar composed of marble dust and stone waste - filename: aetherius-exterior-rendering-night-seafront.jpg alt: Night-time rendering of the AETHERIUS pavilion by the sea caption: "Night-time rendering with a sea view: light filters through the openings at the top and the edges of the moulded modules." faq_count: 6 related_slugs: - first-stone - flowin-footbridge - urban-dunes cta: title: Are you looking into 3D printing for an architectural project? body: If you have a concept with complex geometries that need to be translated into printable components, or if you want to understand how additive manufacturing can work with recycled materials, we can assess the feasibility together. BCA designs for 3D printing and coordinates the fabrication process. button: Send us your brief microcopy: "[Send your brief]" hero_image: aetherius-exterior-rendering-day.jpg gallery_renders: - filename: aetherius-exterior-rendering-day.jpg alt: Daytime rendering of AETHERIUS in a natural setting caption: "Daytime rendering: the pavilion blends seamlessly into its surroundings, with its organic form interacting with the surrounding landscape." - filename: aetherius-exterior-rendering-day-seafront.jpg alt: 3D-printed module made from recycled concrete aggregates (RCA) mortar caption: Detail of the structural module extruded from a mortar composed of marble dust and stone waste - filename: aetherius-exterior-rendering-night-seafront.jpg alt: Night-time rendering of the AETHERIUS pavilion by the sea caption: "Night-time rendering with a sea view: light filters through the openings at the top and the edges of the moulded modules." - filename: aetherius-exhibition-model-full-view.jpg alt: Detail of the 3D-printed underside texture caption: The three-dimensional texture of the soffit, created by extrusion printing, is modular in its modulation of light and acoustics in interior spaces - filename: aetherius-physical-model-chair.jpg alt: "AETHERIUS physical model: structural detail" caption: "Physical model of the pavilion: this section shows the internal geometry and the arrangement of the openings." --- # AETHERIUS — Modular 3D-printed pavilion made from recycled concrete aggregates (RCA) _An organic structure where additive manufacturing transforms waste from the stone industry into architecture for the city._ **2024 · Puglia · Pavilion · 3D Printed Design** --- ## When waste becomes structure AETHERIUS stems from a desire to demonstrate that architectural 3D printing can generate forms of great geometric complexity using materials with a low environmental impact. The pavilion is conceived as a modular structure printed by extrusion, whose mortar is composed of marble dust, stone and aggregates recovered from the stone industry. This approach tackles two issues simultaneously: the search for new applications for additive manufacturing on an architectural scale and the reuse of industrial waste that would otherwise end up in landfill. The design challenge lay in reconciling an organic, fluid morphology — inspired by natural forms — with the technical constraints of the extrusion process. Each module had to be printable as a standalone unit and assembled sequentially, ensuring structural continuity and formal coherence. The large openings at the top are not an aesthetic gesture but a deliberate strategy: they allow natural overhead light and natural ventilation to enter, reducing the need for artificial lighting and air conditioning. The most distinctive feature of AETHERIUS is the three-dimensional texture of the soffit, generated directly by the printing process. Rather than concealing the traces of additive manufacturing, the design transforms them into a spatial quality: the 3D-printed layers are enhanced by the interplay between natural light and the sinuous three-dimensionality of the structure. The integration of trees into the structure — which grow through the upper openings — dissolves the boundary between architecture and landscape, making the pavilion a hybrid organism between the built and the natural. The project has been developed in collaboration with B&Y Srl and is conceived as a replicable prototype: the modularity of the system allows the configuration to be adapted to different contexts, from temporary installations to permanent public spaces. AETHERIUS demonstrates that 3D printing is not merely an alternative construction technique, but a design paradigm that allows for the simultaneous rethinking of form, material and process. --- ## Image gallery ![AETHERIUS physical model structural detail](images/aetherius/aetherius-physical-model-chair.jpg) *Physical model of the pavilion: the section shows the internal geometry and the modulation of the openings.* ![Detail of 3D-printed soffit texture](images/aetherius/aetherius-exhibition-model-full-view.jpg) *The three-dimensional texture of the soffit, generated by extrusion printing, modulates the light and acoustics of the interior spaces* ![Daytime rendering of AETHERIUS in its natural setting](images/aetherius/aetherius-exterior-rendering-day.jpg) *Daytime rendering: the pavilion integrated into its surroundings, with its organic volume interacting with the surrounding landscape.* *Trees integrated into the structure grow through the openings, blurring the boundary between architecture and nature* ![3D-printed module using recycled concrete aggregates (RCA) mortar](images/aetherius/aetherius-exterior-rendering-day-seafront.jpg) *Detail of the structural module extruded using mortar composed of marble dust and stone waste* *Additive manufacturing by extrusion allows for organic geometries impossible with traditional construction methods* ![Night-time rendering of the AETHERIUS pavilion by the sea](images/aetherius/aetherius-exterior-rendering-night-seafront.jpg) *Night-time rendering with sea view: light filters through the top openings and the edges of the printed modules.* --- ## Technical specifications - **Year:** 2024 - **Client:** B&Y Srl (collaboration) - **Typology:** Modular pavilion - **Status:** Concept - **Designers:** Maurizio Barberio, Micaela Colella (Barberio Colella Architetti) - **Collaborators:** B&Y Srl - **Main materials:** 3D-printed mortar with marble dust, stone and recycled concrete aggregates (RCA) - **BCA Vertical:** 3D Printed Design (primary) · Sustainable Design (secondary) --- ## How can an architectural structure with organic geometries be created using recycled materials? Those who design pavilions or temporary structures often find themselves at a crossroads: choosing simple, cost-effective forms that lack identity, or complex geometries that come with high costs and waste. Additive manufacturing opens up a third way, but most architectural 3D printing projects use conventional cementitious mortars, shifting the problem without solving it. AETHERIUS demonstrates that it is possible to print structures of great formal complexity using recycled concrete aggregates (RCA) — marble dust and stone dust that would otherwise be waste — transforming an environmental problem into a design resource. --- ## Frequently Asked Questions ### How does extrusion-based architectural 3D printing work? Extrusion-based 3D printing deposits successive layers of mortar through a nozzle controlled by a robotic arm or a Cartesian gantry. Each layer solidifies and supports the next, allowing complex shapes to be built without formwork. In AETHERIUS, the mortar consists of marble dust, stone powders, and aggregates recovered from the stone industry, mixed with binders that ensure structural strength. The process enables the production of modules with organic geometries and surface textures that would be impossible or uneconomical using traditional methods. ### Which recycled materials can be used in 3D printing for architecture? Waste from the stone industry — marble dust, granite and travertine powders — are among the most promising materials for architectural 3D printing. Reduced to fine aggregates, they can be incorporated into printable mortars that retain good mechanical properties and a natural material appearance. The advantage is twofold: it reduces material procurement costs and avoids the disposal of tonnes of processing waste in landfill. AETHERIUS uses precisely this type of mortar, demonstrating that material recovery does not compromise the quality or complexity of the final result. ### Is a 3D-printed pavilion structurally safe? The structural safety of a 3D-printed component depends on three factors: the mortar formulation (compressive and tensile strength), the component’s geometry (topological optimisation) and the printing process (inter-layer adhesion, absence of defects). In AETHERIUS, the organic form is not random: it is designed to distribute loads efficiently through double-curved surfaces, which function as structural shells. Furthermore, during the detailed design phase, each module is verified using finite element analysis prior to printing. ### How much does a 3D-printed pavilion cost compared to a traditional one? The cost of a 3D-printed structure depends on the scale, geometric complexity and technology used. For complex geometries such as those of AETHERIUS, 3D printing can be more cost-effective than traditional methods because it eliminates the cost of formwork — which for organic double-curved shapes can account for 40–60% of the total cost. The use of recycled concrete aggregates (RCA) further reduces material costs. Fixed set-up costs (robotic arm, calibration) make the technology more cost-effective for series of repeated modules with parametric variations, as in the case of AETHERIUS. ### Is the surface texture of 3D printing a flaw or a quality? In architectural 3D printing, visible layering can be a flaw (if uncontrolled) or a design quality (if intentional). In any case, the texture of the underside is also carefully designed: the printing parameters — speed, layer height, distance between passes — are calibrated to generate a three-dimensional relief that modulates overhead light and improves the acoustic performance of interior spaces. The texture is not a by-product of the process, but a design objective. ### Is it possible to integrate natural elements — such as trees — into a 3D-printed structure? AETHERIUS integrates trees that grow through the structure’s upper openings. This requires a design that takes into account the current and future dimensions of the root system and canopy, additional loads (weight, wind), and water management. The zenithal openings in AETHERIUS are sized to allow the trees to grow whilst simultaneously providing natural light and natural ventilation to the interior spaces. The integration of vegetation and structure is a bioclimatic design principle that improves thermal comfort and air quality. --- ## Are you exploring 3D printing for an architectural project? If you have a concept with complex geometries that need to be translated into printable components, or if you want to understand how additive manufacturing can work with recycled materials, we can assess the feasibility together. BCA designs for 3D printing and coordinates the manufacturing supply chain. **[Send your brief]** _[Send your brief]_ --- ## Related projects - **First Stone** — 3D-printed housing units in New Orleans - **Flowin Footbridge** — 3D-printed steel pedestrian bridge - **Urban Dunes** — 3D-printed shading structure in Abu Dhabi _Discover our approach to 3D Printed Design →_