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This paper is motivated by the renewed interest in space exploration and the need to provide structurally sound and resource‐efficient shielding solutions for valuable assets and future habitable modules. We present, implement and test a methodology for the preliminary design and assessment of optimal arch forms subjected to self‐weight as well as seismically induced loads. The numerical framework, built around a limit thrust‐line analysis, previously published by the authors, is summarized first. This is followed by a detailed account of the form‐finding algorithm for arches of variable thickness. Special attention is placed on the physical feasibility of our assumptions and the justification of the engineering inputs adopted. The newly form‐found arches achieve material efficiencies between 10% and 50% in comparison with their constant minimum‐thickness circular or elliptical counterparts, depending on the relative intensity of the seismic action. The influence of the initial input geometry and the stabilising presence of additional shielding material against extreme radiation are also evaluated with emphasis on the effects of low‐gravity conditions. Finally, a case study is presented and Discrete Element Models of constant and varying thickness arches (VTAs) are assessed under a set of representative ground‐motions on a lunar setting. The significant over‐conservatism of constant thickness arches (CTAs) is made manifest and potential improvements of the optimally found arch shape are highlighted. Although developed with extraterrestrial applications in mind, the results and methods we present herein are also applicable to terrestrial conditions when material efficiency is of utmost concern.

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