The construction industry stands on the edge of a technological revolution, with 3D printing technology redefining the usual building process. This innovative technology, also known as additive manufacturing, has changed how we design and construct our built environment. 3D printing, a subtype of additive manufacturing, is a process of creating a physical object from a digital model. This technology has been rapidly advancing in recent years and has found a wide range of applications, including in the construction industry.
In construction, much of the information needed to make this technology work derives from the design process. The integration of 3D printing technologies is less complicated. A 3D printer takes instructions from a CAD or BIM program and builds the object by layering materials as directed. This is done with various materials, the most common being a mixture of concrete, geo polymers, fiber, and sand.
Digital fabrication techniques
At present, the combination of digital fabrication techniques and cementitious materials has led to the development of innovative manufacturing processes for fabricating concrete-like products, objects, and structures. These include layered extrusion, binder jetting, and slip-forming.
Most developments in digital fabrication of concrete-like products have been focused on layered extrusion technology (such as contour crafting, and concrete printing), as its operating procedure is based on the more widespread production scheme of polymeric customized parts. However, its implementation in construction processes requires much larger printers than those used for metal or plastic objects, due to the dimensions of the final objects to be printed.
Typically, the automated machinery used for the layered extrusion of concrete includes a digitally controlled moving printing head. It precisely lays down the concrete or mortar material layer by layer. This allows the opportunity to create customized structures and functional voids into the printed elements. The manufacturing technology facilitates the development of on-site constructions in one single stage. This reduces the transportation of construction equipment, assembly operations, labor costs and the risk of injuries during construction works. Stanford’s Center for Design Research collaborated with ICON, a company specializing in 3D printing for construction, to develop new methodologies for efficient building processes in 2020. This partnership aimed to improve the scalability and adaptability of 3D-printed structures.
3D concrete printing
3DCP is an automated additive manufacturing technique, which uses either a gantry or robotic arm printer to print successive layers of concrete, one on top of the other. It allows limitless geometric configurations for the printed elements or walls, which provides architectural freedom. Although 3DCP technology is a relatively new technology, it is currently attracting a lot of attention because of its advantages of low waste generation, sustainability, construction duration, construction costs, and worker safety. The University of California, Berkeley, partnered with ICON in 2022 to explore the use of 3D concrete printing in creating disaster-resistant housing. This collaboration aimed to utilize the speed and efficiency of 3D printing to provide safe shelter in areas prone to natural disasters.
3DCP creates almost zero waste, requires less transportation during the construction process, and hence has a lower carbon footprint. Furthermore, it reduces the number of trees cut for timber formwork and minimizes the post-construction waste from the used and unused formwork molds. Moreover, the absence of formwork causes a significant reduction in construction cost and duration. Besides the reduction in labor, 3DCP also offers an improvement in the health and safety of the workers during construction, especially in harsh environments.
Alternative climate mitigating solutions
Beyond its existing commercial applications in 3D printing construction market, C3DP has the potential to limit greenhouse gas emissions from the cement supply chain in the production of printable cementitious mixtures. New low-carbon 3D printable cementitious mixtures have been developed with supplementary cementitious materials including industrial wastes and natural materials, alternative binders, and recycled materials. This reduces emissions on the production side of the cement supply chain. Through structural design optimization and functional hybridization in construction, C3DP is used to fabricate structures that use less cementitious materials, decrease the need for formwork, and reduce waste, lessening emissions compared to conventional concrete construction. For instance, China has also included additive manufacturing in its national development strategies for “manufacturing core competitiveness” as outlined in the 14th Five-Year Plan, which has resulted in an increase in government research funding for C3DP.
BioHome3D and Citizen Robotics’ 3D-printed home
The University of Maine Advanced Structures and Composites Center is 3D-printing housing structures exclusively from bio-resins and wood fibers. This is for combating labor shortages and widen access to affordable buildings. The demo project, known as BioHome3D, begins with a 600-square-foot prototype that features a fully 3D-printed floor and roof. As a whole, the one-bedroom, one-bathroom building is 100 percent recyclable, made up entirely of biodegradable materials, including wooden floors. As a prototype, BioHome3D is equipped with monitoring sensors, measuring thermal, environmental, and structural elements, to gather resilience-based data to better inform future designs.
In 2023, housing construction company Citizen Robotics built the first 3D-printed house in Michigan, with design assistance from develop ARCHITECTURE and the president of the Detroit chapter of the National Organization of Minority Architects. Citizen Robotics applies robotic and automated construction techniques to reduce the costs and materials needed for home construction. A 1,000-square-foot, two-bedroom home, along with its attached wall segments, was 3D-printed at the company’s facility in Southwest Detroit and later transported and assembled on-site in the Islandview neighborhood of Detroit. The home became available for purchase in 2024.
Final thoughts
The significant area of progress in 3D printing in construction is the development of new materials, such as sustainable and biodegradable materials, that can be used in 3D printing. Additionally, printing techniques have become more precise and efficient, allowing for the creation of larger and more complex structures. Software advancements have also assisted architects and engineers to create intricate designs and simulate the performance of structures before they are built. Furthermore, mobile 3D printing machines have been developed, making it possible to print 3D structures on-site, reducing transportation and assembly costs.
✍ **𝑨𝒓𝒕𝒊𝒄𝒍𝒆 𝒘𝒓𝒊𝒕𝒆𝒓: Saranya Ganguly
Author’s Bio:
Saranya Ganguly is a B2B writer with extensive experience in crafting research-driven content. Her interests concern sustainability, BFSI, and technology. The knack for blending insights and statistics with creative flair motivates her to deliver engaging, and impactful write-ups. She specializes in web articles, newsletters, promotional pieces, and LinkedIn briefs, helping businesses articulate their brand voice and value propositions. A master’s degree holder in English and Commonwealth Literature, Saranya enjoys reading in her free time. When not writing, she dabbles in photography and fine art.
