Koç University researchers have developed a conservation method that combines photogrammetry, digital modeling, 3D printing and embedded sensors to replace missing sections of archaeological amphorae. The customized fills can also monitor environmental and physical changes affecting the artifacts, offering a systematic approach to their conservation and long-term preservation.
Imagine recovering a 1,000-year-old amphora from the seabed. After centuries underwater, it may be cracked, encrusted or missing pieces. How can it be reconstructed without causing further damage—and how can conservators continue to monitor its condition once it is displayed or stored?
For centuries, conservators have commonly used plaster to replace missing sections of ceramic artifacts. Although effective, these repairs cannot provide information about environmental changes or physical stresses that may threaten the object over time.
A team of archaeologists and engineers from Koç University has developed a different approach. In a study published in the Journal of Cultural Heritage, the researchers describe a method combining photogrammetry, digital modeling, additive manufacturing and embedded sensors to produce customized “smart” fills for damaged archaeological ceramics.
The study was conducted by Savannah Ulalian Bishop, Munam Arshad, İsmail Lazoğlu, Matthew Harpster and Hammad Ur Rehman through a collaboration between Koç University’s Mustafa V. Koç Maritime Archaeology Research Center (KUDAR) and Manufacturing and Automation Research Center (MARC).
The process begins with a camera. Hundreds of overlapping photographs of an amphora are combined using photogrammetry software to create a precise digital three-dimensional model. Researchers can then digitally reconstruct the missing section and produce a customized fill using 3D-printing technology.
Unlike a conventional plaster repair, however, the printed fill can contain integrated sensors. These sensors are designed to detect changes in temperature, humidity, pH and physical stress—all of which may affect the stability of archaeological objects. Because the sensors are incorporated directly into the repair rather than positioned elsewhere in the museum, they can provide information about the conditions affecting the individual artifact.
Changes in humidity, temperature or stress can contribute to salt migration, deformation, microfractures and other forms of deterioration. The sensorized fills could therefore allow conservators not only to reconstruct missing parts but also to monitor potential risks after restoration.
The researchers developed and tested the methodology using maritime amphorae from two collections: Günsenin IV amphorae recovered from the late Byzantine Çamaltı Burnu I shipwreck and displayed at the Bandırma Archaeology Museum in Türkiye, and a mixed collection of amphorae from the Amalfi coast held at the Minori Villa Romana e Antiquarium in Italy.
Initial museum measurements showed that the integrated sensors could record daily changes in temperature and humidity as well as patterns of force detected by a stress sensor. The study primarily presents and evaluates the methodology; further work will examine its results, practical applications and cost-effectiveness.
The approach is intended to establish a reproducible process for documenting archaeological ceramics, reconstructing missing sections and monitoring their stability. It may be particularly valuable for maritime artifacts, which often require individualized treatment because of the mechanical, chemical and biological deterioration they experience underwater.
By combining conservation, archaeology and engineering, the method turns the replacement piece into more than a passive repair. The 3D-printed fill becomes part of a system that can both restore an artifact’s form and provide information about its condition, supporting its long-term preservation.