Building ICONs Catenary Dome (2025-10)¶

A full-scale 3D-printed dome was constructed in partnership between construction technology company ICON and structural firm Walter P. Moore (WPM). The project aimed to build a funicular-based dome replicating classic masonry techniques, enabling a more efficient form that mitigated current constraints when 3D-printing shell structures. Constraints include the maximum cantilever angle, vertical reinforcement installation, and geometric instability. The solution employs two distinct catenary profiles—a steeper upper cap connected to a shallower base—with a bond beam that resolves thrust forces. This maximizes usable space and enables a dome closer to a hemisphere than a single catenary profile allows. ICON developed the design and executed the build while WPM conducted an FEA of the shell, confirming the compression-dominant behavior and the elimination of vertical reinforcement. This approach establishes a framework where 3DCP can utilize principles from traditional masonry, enabling more efficient shell structures and expanding possibilities in cementitious additive construction.