The Ceramic Vault is an experimental architectural prototype developed at the Built Environment Department of Eindhoven University of Technology. Students Jan-Willem Melchers, Thijs Maas Geesteranus and Dena Khaksar created the project under the supervision of Professor Cristina Nan and architect Mattia Zucco. The research explores how 3D clay printing can reinterpret historic construction principles using contemporary digital tools.

The project draws inspiration from the ruins of the Maxentius Basilica in Rome’s Forum Romanum. Roman architecture represents a turning point in construction history, where material knowledge, structure and expression came together. In this context, the brick played a central role. Therefore, the project uses the brick as both a historical reference and a starting point for material innovation.

From Historic Brick to Digital Ceramic Components

Rather than copying historical forms, the designers focused on one of the Basilica’s missing vaults. They used this absence as an opportunity to test how computational design and robotic fabrication can reshape traditional ceramic construction. As a result, the brick transforms from a standard building unit into a digitally driven ceramic element.

The design process begins with structural analysis. The internal force flow and stress lines of the vault, which usually remain hidden, guide the geometry of the ceramic tiles. Through a sequence of simulations and evaluations, these forces become visible and tangible. Consequently, structure and ornament merge into a single material expression.

Material Behaviour and Fabrication Challenges

Working with clay at an architectural scale presents clear challenges. Clay shrinks unevenly during drying and firing, and it easily deforms under its own weight. In addition, the project aimed for a dry assembly without adhesives, which required high dimensional accuracy.

To address these issues, the team combined material testing, computational modelling and physical prototyping. They continuously adjusted the digital design based on the measured behaviour of the clay. As a result, shrinkage compensation and deformation control became an integral part of the robotic production workflow.

Sustainability Through Digital Craft

Clay is a natural, widely available and low-impact material. When paired with digital fabrication, it offers new opportunities for sustainable construction. Robotic 3D printing enables precise material use, reduces waste and supports local production. At the same time, it allows designers to embed structural intelligence directly into the material form.

Connecting Heritage, Technology and Future Architecture

The Ceramic Vault demonstrates how ceramics can bridge craftsmanship, computation and sustainability. For architects, interior designers and product designers, the project highlights the potential of advanced ceramics as expressive and resource-efficient building materials. Ultimately, it shows how historical knowledge can actively inform future material innovation.

Source & photos: Eindhoven University of Technology / Cristina Nan