Vaulted cap ceilings represent architecturally and structurally sophisticated constructions commonly found in historic buildings. However, they are rarely used in contemporary construction due to high manufacturing costs, complex formwork processes, and limited compatibility with modern industrial construction processes. This paper investigates the potential of 3D concrete printing as an innovative manufacturing process that combines the traditional design of vaulted ceilings with the need for cost-effectiveness, sustainability and prefabrication. Inspired by historical vaulted ceilings, curved load-bearing structures have been developed that can be manufactured using an additive fabrication process and installed between primary supporting structures. Parametric design and computational analysis methods were employed throughout the process to enhance material efficiency and structural performance. In addition to automating construction processes, 3D printing enables the formwork free production of complex geometries and targeted material placement. The result is load-bearing structures with high load-bearing capacity and minimal use of materials. This makes it possible to economically implement curved load-bearing structures. Physical prototypes of the developed systems were manufactured and subjected to mechanical testing to assess their load-bearing behaviour. The experimental data shows strong agreement with numerical stress simulations, confirming the predictive accuracy of the digital models. The results highlight the high structural efficiency, dimensional stability and mechanical reliability of the proposed systems. Beyond structural performance, the environmental impact is significantly reduced. By minimizing material usage and eliminating the need for conventional reinforcement, CO₂ emissions are substantially lower than those of traditional concrete ceiling systems. The integration of digital design and automated fabrication processes establishes vaulted cap ceilings as a viable, resource- efficient and architecturally expressive sustainable construction solution.