Computational Tectonics .lab | Ecologically Active Structures

Ecologically Active Structures

2022

University of Virginia

Research Project

Ehsan Baharlou, Dr.-Ing.

Robotically 3D-Printed Soil Structures that Support Plant Life, from Proof-of-Concept Domes to Germinating Wall Systems

This project investigates soil as a living construction medium by integrating robotic additive manufacturing with ecological performance. It begins by establishing a proof of concept at the material and prototype scale, demonstrating that extruded soil can function simultaneously as a structural and biological substrate, and then advances toward architectural application through scalable wall systems. By coupling soil mechanics, plant growth, and computational fabrication, the research frames geometry and layering as active agents in controlling water retention, germination, and environmental interaction, positioning ecologically active structures as a foundation for resilient and regenerative architectural tectonics.

Phase1: Analysis

This research on ecologically active structures explored the feasibility of 3D printing soil structures capable of supporting plant life. The study successfully printed self-standing soil domes from soil alone, without stabilizing additives, using robotic paste extrusion. When water content is properly controlled, these printed structures support the germination and growth of plants, and their water-retention behavior differs from that of potted soil of the same composition.

By examining three different soil textures, our research team correlated drying characteristics with the soil’s ability to support plant growth and revealed a fundamental difference in the soil-water characteristics of extruded soils. The work highlights the importance of a printable mixture that is both structurally cohesive and able to provide nutrients for seed germination. Robotically 3D-printed, self-standing domes serve as living structures at the prototype scale, opening the conversation on the role of geometry in water retention for free-standing structures.

Published in Additive Manufacturing (2022).

Program Development

Top views of three soil samples with different plant species.

© CT.lab, University of Virginia.

Dome-shaped soil print with scattered seeds on its surface.

Adapted from Barnes et al., Additive Manufacturing (2022); © CT.lab, University of Virginia.

Dome surface densely covered with sprouts and visible roots.

Adapted from Barnes et al., Additive Manufacturing (2022); © CT.lab, University of Virginia.

Close-up of small green sprouts growing from soil.

Adapted from Barnes et al., Additive Manufacturing (2022); © CT.lab, University of Virginia.

Soil domes shown without plants and then covered in sprouts.

Adapted from Barnes et al., Additive Manufacturing (2022); © CT.lab, University of Virginia.

Phase 2: Application

Building on this initial work, a second phase explores scalability at the stud-wall level. The research expands traditional earthen construction by incorporating robotic 3D printing to embed greenery within each layer. Framed as Ecotectonics, a synthesis of environmentally responsive strategies and living construction, the robotic extrusion of soil-based mixtures continues to meet the project’s three core criteria of printability, structural cohesion, and nutrient capacity while extending these qualities to larger assemblies.

In the wall-partition prototype, successive soil layers are robotically deposited and selectively seeded so the exterior face germinates while the interior remains finish-ready. By incorporating living components into the printed soil, the result shows that living, performance-enhancing skins can be integrated directly into wall assemblies without a separate cladding system, advancing both resilience and circular material practice.

This second phase was developed and published as sole author under the framework of Ecotectonics (Homing the Machine in Architecture, Routledge, 2024), extending the earth-printing method first presented as Mud Tectonics (AIA/ACSA Intersections).

Program Development

Diagram showing soil grinding, mixing, pumping, and robotic printing in a circular process.

© CT.lab, University of Virginia.

3D-printed soil wall with layered texture and hollow cavities.

© CT.lab, University of Virginia.

Three images showing increasing plant coverage over time.

© CT.lab, University of Virginia.

Soil wall covered with dense green sprouts in a lab setting.

© CT.lab, University of Virginia.

Diagram and photos showing seeds applied only to the outer wall face.

© CT.lab, University of Virginia.

This research was exhibited as a multi-panel display at the French Pavilion of the 19th Venice Architecture Biennale (Vivre Avec / Living With, 2025) and at the 6th Chicago Architecture Biennial (SHIFT, 2025-2026), where it was presented on an opening-weekend panel, and at the Frac Centre-Val de Loire, Orléans (2026). It was named a Best Practice in the Zukunftsinstitut Home Report 2023 and covered by international outlets including Dezeen and Fast Company.

Venue

Additive Manufacturing (2022); Mud Tectonics: Exploring Eco-Friendly Approaches to Robotically 3D-Printed Earth Construction (AIA/ACSA Intersections, 2023, sole author); chapter in Homing the Machine in Architecture (Routledge, 2024, sole author); French Pavilion, 19th Venice Architecture Biennale (2025); 6th Chicago Architecture Biennial (2025-26); Frac Centre-Val de Loire, Orléans (2026)

Role

Project Lead (architectural side): Phase 1 collaborative; Phase 2 (stud-wall) developed solely

Design Method

Computational Design (Grasshopper Workflows)

Fabrication Process

Additive Manufacturing (Robotic Paste / Ink Extrusion; Potterbot extruder, Phase 1 domes)

Building Material

Mineral Composite (Soil-Based Ink, Sand, Kaolinite Clay); Biogenic Additive (Microgreens: White Clover Seeds)

Construction System

Printed Component (Soil Domes / Walls); Ecologically Active (Soil Prototype, Earthen Wall)

Environmental System

Vegetation Integration (Plant Germination, Multi-Species Growth, Seed Integration)

Final Wall Prototype Dimensions (Phase 2)

W 406 mm × D 170 mm × H 600-900 mm (≈ 16 in × 6.7 in × 24-35 in)

Project Team

Ehsan Baharlou (Project Lead), David E. Carr, Ji Ma

Student Research Assistants

Phase 1: Spencer Barnes, Leah Kristin Kirssin, Elizabeth Needham

Image Credit

Computational Tectonics Lab (CT Lab), University of Virginia, 2022-2024

Acknowledgements

Developed at the Computational Tectonics Lab (CT Lab), School of Architecture, University of Virginia, with project lead Dr.-Ing. Ehsan Baharlou and collaborators David E. Carr and Ji Ma. This work was supported by the University of Virginia 3 Cavaliers Program.