The rapid advancement of 3D printing in construction is transforming what was once considered a futuristic idea into a tangible reality. Over the last few years, numerous companies have poured significant resources—millions of dollars—into research and development to leverage this technology and revolutionize the building sector.
As the construction industry grapples with rising material costs and a shortage of skilled labor, businesses are seeking innovative solutions to boost productivity and minimize material wastage. 3D printing has emerged as a promising solution as the technology continues to refine and expand its capabilities.
Understanding 3D Printing
3D printing, also known as additive manufacturing, is a process that fabricates three-dimensional solid objects directly from a digital file. Similar to printing a document on paper, a 3D printer constructs an object layer by layer from the ground up, starting with raw materials like plastic or cement. Unlike subtractive manufacturing, which removes material to shape an object (like a CNC machine), 3D printing significantly reduces waste and opens up possibilities for more intricate designs.
Because 3D printing builds objects layer by layer, it can create complex structures that subtractive manufacturing simply cannot achieve. For instance, hollow or lattice structures that require precise internal geometry can be effortlessly printed, whereas traditional machining might struggle to access certain areas to carve them out.
Lattice structure created by Branch Technology
Source: Branch Technology
Consumer-grade 3D printers typically use melted plastic filaments to create small items, similar to how a hot glue gun works. However, industrial-grade 3D printers can handle more advanced materials such as metals and high-performance plastics, often employing lasers and other precision tools to bond the materials effectively.
Building Homes and Structures with 3D Printing
In recent years, several startups and established players in the construction industry have focused on developing large-scale 3D printers capable of constructing homes, office buildings, and other massive structures. Experts anticipate that this technology will drastically reduce costs and shorten construction timelines.
Contour crafting—a method of 3D printing for construction—uses computer-controlled cranes or gantries to rapidly and efficiently build structures with minimal manual intervention. Most construction 3D printers extrude a cement-like material that hardens over time.
The development of a cement-based material suitable for 3D printing presents a major challenge. It must be easy to pump and extrude, quickly gain sufficient load-bearing strength to support upper layers, and maintain strong bonds between layers.
- Dr. Jennifer Scheydt, Head of Engineering & Innovation at HeidelbergCement Germany
3D-printed homes hold the potential to make housing more affordable globally since the cost of manufacturing such homes is far lower than traditional wooden-frame constructions. Additionally, these homes boast superior insulation due to their cement walls featuring air gaps.
ICON Builds the First Permitted 3D-Printed Home in the USA
In 2018, ICON, a construction technology company based in Austin, Texas, constructed the first legally approved 3D-printed home in the United States. Using their portable Vulcan printer, ICON built a simple yet cost-effective 650-square-foot home in under 24 hours for less than $10,000.
Traditional construction methods come with inherent inefficiencies and problems we've accepted for too long. With 3D printing, we not only achieve continuous thermal envelopes, high thermal mass, and near-zero waste, but also unparalleled speed, a wider range of design options, enhanced resilience, and the potential for unprecedented affordability. This isn't just 10% better—it's 10 times better.
- Jason Ballard, Co-founder of ICON
ICON's first 3D-printed house in Austin, Texas
Source: iconbuild.com
Raw Earth 3D-Printed Mud Homes
In 2021, Mario Cucinella Architects completed a sculptural home in Ravenna, Italy, entirely made of 3D-printed raw mud. The 645-square-foot TECLA home took approximately 200 hours to build.
Named after "technology" and "clay," TECLA represents a significant leap forward in 3D home printing because it uses 100% locally sourced materials (raw earth) without cement. Two synchronized 3D printing arms (WASP Crane 3D printers) worked together to avoid collisions while printing simultaneously.
TECLA's "circular housing" design provides structural integrity without relying on self-hardening materials like cement. Sourcing materials from the local terrain drastically lowers greenhouse gas emissions compared to conventional 3D-printed homes, making this approach both eco-friendly and cost-effective.
For this project, Mario Cucinella Architects not only explored architectural aesthetics but also studied the home's shape in relation to its climate and latitude. The composition of the earth mixture adapts to local climatic conditions, and the filling of the envelope is parametrically optimized to balance thermal mass, insulation, and ventilation based on the region's needs. TECLA consists of two continuous elements forming a sinuous sine curve culminating in two circular skylights symbolizing the 'zenith of light.'
- Mario Cucinella Architects
Source: Mario Cucinella Architects
The Process of Printing a Home
- A designer creates a 3D model of the home on a computer. The model can easily be resized and reused.
- The 3D model is converted into instructions for the 3D printer, providing precise coordinates and movements to construct the cement walls.
- Workers prepare the home's foundation, usually involving pouring a concrete base. At present, foundations are not 3D printed, though this may change in the future.
- The 3D home printer is set up at the construction site. Workers prepare and feed the concrete mix into the printer.
- The printer begins printing. Workers stand by to assist if the 3D printer encounters an issue or requires help completing openings for doors and windows.
- Layers are stacked until the walls form. The process runs continuously.
- The concrete is allowed to dry and harden.
- Workers return to paint, add the roof, doors, and windows, and install electrical fixtures and plumbing.
3D-Printed Homes Provide Promising Humanitarian Solutions
Natural disasters such as hurricanes, earthquakes, and tornadoes devastate thousands of homes annually across the globe. Many families remain homeless for extended periods, facing severe financial strain. 3D-printed homes could offer an inexpensive and efficient way to rebuild and house displaced families in disaster zones.
3D printers themselves can be transported via cargo ships and assembled at construction sites relatively quickly. Furthermore, most regions worldwide possess the basic materials necessary to produce the cement mixtures required for 3D home printing.
Source: iconbuild.com
Every New Technology Evolves Over Time
Current 3D-printed homes will continue to improve as we uncover better materials and processes. Challenges persist, such as stress fractures in concrete walls, reducing human involvement in creating openings for doors and windows, building multi-story structures, and enhancing resilience against natural disasters.
Some companies are experimenting with contraction joints (similar to sidewalk cracks) to prevent stress fractures. Others are exploring different cement mixtures and wall designs to optimize the extrusion and hardening of the cement.
Over time, technological advancements will lead to breakthroughs that improve materials and processes. We might eventually see entire communities of homes built by 3D printers in mere weeks rather than months.
Resources
New Story + ICON: 3D Printed Homes for the Developing World
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