Since 3D construction printing first emerged in the 2010s, it has grabbed huge attention as it could be a new revolution of architecture that will change the world. 3D Concrete Printing is a promising technology that can revolutionize the construction of buildings and structures into new and complex forms, saving time, materials, labor, and costs while enhancing construction’s sustainability and environmental impact. Yet, it is still in the settling stage for various reasons and would still take time to be applied to the actual field of architecture.
3D construction printing is a relatively new technology and a broad concept. This article will briefly introduce the technology, how people foresee using it in the real world, and its benefits and challenges. Also, looking into the actual application that has brought social impacts will be a good overall guide to grasping 3D construction printing.
3D construction printing, also known as 3DP, is an automated process that manufactures construction elements or entire structures using a 3D printer. This innovative technology, often called additive manufacturing or additive construction, uses industrial-grade 3D printing to build materials layer by layer. The versatility of 3DP is evident in its ability to be carried out both onsite and offsite, opening up a world of possibilities for the future of construction.
Types of Construction 3D Printers
There are mainly two types of construction 3D printers frequently used at the construction site: the robotic arm and the gantry system.
Robotic Arm
A robotic arm is an automatically controlled printer that allows freedom of movement and flexibility to schedule multiple tasks. The arm is capable of printing from multiple angles, allowing the realization of complex geometries and curves and printing in larger sizes compared to other 3D printing methods.
Gantry System
For the Gantry system, the contouring method marks the beginning of 3D printing in construction. This process deposits building material to form a 3D model and create large-scale structures with a smooth surface finish. It works with rails placed around the building floor that act as a guide to direct the robotic arm in applying the concrete layer by layer.
Common Printing Methods and Materials
So far, there is no one-size-fits-all 3D printing construction technology. Depending on the specifics of the project, different printing methods can be employed. Among other methods, such as extrusion, powder bonding, spray, and sand layers, extrusion is the most common 3D printing technique, as it can be used in almost all environments. Commonly used for modeling, prototyping, and production applications, this method creates an object by layering material back and forth through one or more nozzles mounted on a robotic arm, gantry system, or crane.
The material selected should depend on the type of project. Yet the most common materials used include standard concrete, mortar, plastic, metal, and local natural materials such as stone, sand, mud, and rice waste.
The most common 3D printing technology for construction involves a robotic arm that extrudes concrete while moving back and forth.
What are the benefits of 3D construction printing?
Time reduction
With traditional construction methods, a project can take many months to complete, while 3D printing can reduce this time by up to 70%. Depending on its magnitude, a project can be completed in just hours or days.
More cost-effective and sustainable
3D printing allows the precise amount of material to lift a structure, generating up to 60% less waste at the job site. Likewise, there will be no surplus in the purchase of materials, assuming a reduction in costs both in its purchase and subsequent storage. This is because additive manufacturing builds layer by layer, using only the material and energy required to make a particular component. It’s a far more efficient building process than “subtractive methods,” which involve removing excess material.
Safety
One of the most essential benefits that 3D printing has brought to construction is in the health and safety of the employees onsite. By knowing how to work effectively with printers, workers can do their jobs more efficiently and reduce injuries in the field.
Design flexibility
Last-minute changes to the design will no longer be a problem nor delay the construction process. 3D printing allows us to customize the work until just before printing the structure, eliminating all the headaches these changes entail.
Then, what are the challenges of 3D construction printing?
While some roadblocks to the widespread adoption of this technology still exist.
Size and height limitation (durability)
Although some large structures are printable, the printer’s size often limits the finished product’s size. This makes printing large-scale projects difficult and time-consuming. Also, 3D printers cannot build high-story buildings like apartments yet. The highest is almost a four-story building.
Limited materials
3D printing in construction is currently limited to a relatively small range of materials, including concrete, plastics, and composites. This restricts the types of structures you can print and their durability and lifespan.
Quality Control
Ensuring the quality of 3D-printed structures can be challenging, especially since there are no established industry standards or codes for construction with 3D printing.
Lack of regulation and legislation
More regulations and legislation are needed for 3D printing in construction that allows for clear guidelines on its use and the benefits of its implementation in new construction sites. There is still plenty of room for intellectual property and legal violations.
Lack of skilled labor
3D printing requires specialized skills and knowledge that are not yet widely available in the construction industry. There aren’t many qualified workers who can operate and maintain 3D printers in construction settings.
Examples of 3D-printed houses
1. TECLA House, Italy (2021)
The TECLA house is a prototype 3D-printed eco-residential building made of clay in Italy. The Italian architecture studio MCA designed the first model, which was engineered and built by Italian 3D printing specialists WASP in April 2021. It became the world’s first house 3D-printed entirely from a mixture of mainly local earth and water. TECLA responds to the increasingly severe climate emergency, the need for sustainable homes at Km0, and the great global issue of the housing emergency that will have to be faced – particularly in the context of urgent crises generated, for example, by large migrations or natural disasters.
2. Community First! Village (2023)
Community First! Village is a master-planned neighborhood that provides affordable, permanent housing and a supportive community—a forged family—for men and women coming out of homelessness. Development of Mobile Loaves & Fishes, this transformative residential program exists to love and serve our neighbors living on the streets while empowering the surrounding community to live a lifestyle of service to people experiencing homelessness. ICON, a con-tech company, 3D printed a 500 sq. ft. ‘Welcome Center’ and printed three homes at a time for a series of six homes for residents of the Community First! Village.
3. Nacajuca, Tabasco, Mexico (2019)
The last example of 3D-printed housing is a village in Nacajuca, Mexico. It was a project by New Story, a non-profit organization, in partnership with Échale and ICON. They 3D-printed the houses for residents living in poverty. Each resilient 500 sq ft home was printed in about 24 hours and features two bedrooms, a living room, a kitchen, and a bath. The homes can tolerate extreme conditions and have already withstood a magnitude 7.4 earthquake.
To conclude, 3D construction printing has a huge potential to be the next revolutionary construction method and change the current construction field. Despite the challenges and lack of infrastructure that the technology needs to be standardized, 3D construction printing would bring huge savings on time, material, and money.
Just as introduced above, current applications to bring a positive social impact have been focusing on providing housing to people who are experiencing homelessness. However, even though it is a good intention, we should consider potential concerns as well because 3D-printed houses are not yet fully authorized in terms of safety in the long term. Applying the new technology to the vulnerable is something we should be careful and considerate of. New technology can be a revolution, but being efficient is not only the best decision we should take.
Sources
Team Xometry, 3D Printing Technology for Construction, 2023
Cemex Ventures, How 3D printing in the construction industry works, 2023
단 140시간 만에 완공된 유럽 최대 규모의 3D 프린팅 건물, 2023
김정희, 세계 각처의 3D 프린팅 주택 사례 ①, 2021
James Rose, 3D printing will transform architecture forever – here’s how, 2023
Alberto Chiusoli, The first 3D printed House with earth | Gaia, 2018
TECLA – Technology and Clay: the first eco-sustainable house 3D printed from raw earth, 2021