Concrete is the most widely used building material on Earth, and producing it is one of the largest single sources of carbon emissions. One promising way to reduce its environmental footprint is to 3D-print concrete, laying it down bead by bead like a giant icing-piping robot. This process eliminates the labor-intensive formwork of pouring it into molds, and places the material only where a structure needs it.

But many of the most efficient designs created by computers are impossible for today’s printers to build. Engineers use a technique called topology optimization to find the strongest structure that uses the least amount of material. But those mathematically ideal designs, with their intricate, spider-web shapes, don’t account for the physical limitations of large-scale concrete printers with their thick nozzles, limited turning, and need to print in one continuous motion.

Now a team of MIT researchers has developed a way to close that gap. Their framework, described in a new article in Additive Manufacturing, bakes a printer’s real fabrication limits directly into the optimization, so the design that comes out is one a machine can build and print with little or no manual redesign. They demonstrated it by designing, printing, and load-testing a 2.3-meter concrete bridge and found that today’s printing hardware, not the concrete itself, limits how light a structure can be.