Building Technologies

Changing the world, one printed house at a time

09 July 2024
Additive manufacturing can be used either on- or off-site and are being used to help make homes more affordable and accelerate the construction process. Source: st.kolesnikov/Adobe Stock

Imagine a future where homes are crafted by enormous robots, their mechanical arms layering concrete, plastic, and composite materials with meticulous precision. A growing number of startups, supported by big names in construction, are already promoting the adoption of three-dimensional construction printing (3DP or 3DCP), an automated process of manufacturing construction elements or entire structures. Instead of using ink, materials are printed in an additive way and carried out either on- or off-site.

3D printing technology addresses some of the most pressing issues in housing today — making homes more affordable, speeding up the construction process and minimizing the specter of a deteriorating environmental footprint. 3DCP options are also offering immense benefits to stakeholders across the entire construction value chain and are becoming an indispensable tool in the modern construction company’s inventory.

Technology

A decade ago, 3DCP was almost unthinkable, since it was too expensive and too difficult to scale across global markets. However, it is fast building a reputation for cutting project schedules by 30%, saving investors 80% on labor and material costs, and reducing material waste by 30% to 60%. And as we look toward 2030, its value is expected to increase to $680 million, representing a 91.5% increase in its compound annual growth compared to 2021 from $190 million in 2021.

A construction project’s success is determined by five essential elements including cost reduction, time management, improvement in public health and safety, and environmental sustainability. From all indications, it would appear the adoption of printed housing yields substantial benefits. Therefore, the best construction strategies today are embracing digital fabrication because of its flexibility, reduced complexity, high performance, intricacy and material customization of material, resulting in far-reaching positive equity, diversity and democratic effects.

Economic implications

The economic benefits of 3CDP are multifaceted. Traditional construction methods are often labor-intensive and time-consuming, leading to higher costs for labor and materials. In contrast, 3DCP substantially reduces these expenses, making homeownership more accessible for diverse populations.

The rapid construction process offers a viable solution for the growing issue of homelessness around the globe. It also lowers the barriers to home purchase in regions where real estate inventory is low. Shrinking reliance on investors and banks for funding and shipments, compressing the production timeline, and reducing the need for slow, unresponsive and international supply networks, means 3DCP is a true market disruptor.

Environmental considerations

Sustainability is a compelling advantage of printed housing. According to the Environmental Protection Agency, construction and demolition debris generated by the construction industry exceeded 600 million tons in the United States in 2018. Much of the waste includes non-recyclable materials like concrete, asphalt, steel, brick, drywall, plaster and wood. This efficiency not only reduces trash but also lowers the overall environmental impact of construction projects.

The materials used in 3DCP printing, such as lightweight concrete mixtures and sustainable composites, require less energy to transport and handle. Printed homes can be designed with more energy-efficient features resulting in less energy consumption and a smaller carbon footprint. Projects like the TECLA (technology and clay) in Ravenna, Italy, exemplify the potential for zero-waste construction and sustainable living environments. They highlight how technology can contribute to a more eco-friendly future in the housing industry by combining innovative design with sustainable practices that stimulate the green economy.

Furthermore, the use of eco-friendly materials like recycled plastics, bioplastics and other sustainable materials reduces the environmental impact. This approach, along with the use of smart technologies, supports a circular economy where materials are reused and recycled. The integration of smart technologies in 3D printing further optimizes the construction process and ensures consistent quality.

Social impact

Communities are increasingly embracing the social benefits of affordable, quickly constructed housing. As labor dynamics in the construction industry evolve, the demand for new skillsets related to 3DCP technology is indeed rising. This shift necessitates a workforce proficient in operating advanced machinery and managing digital construction processes, creating opportunities for specialized training and education. Furthermore, the automation of construction tasks reduces human error and workplace injuries, enhancing overall job safety and making the industry more appealing to prospective workers.

With the social acceptance of printed housing comes more attainable and inclusive residential solutions. The reduction in construction time and costs directly translates into increased availability of affordable homes for low-income families, a sector that has long faced a chronic shortage. Moreover, the accessibility of homeownership for those previously priced out of the market can be a game changer, particularly in regions where real estate inventory is critically low. As more communities witness the tangible success of 3DCP projects, the adoption and integration of this technology are poised to expand, fostering long-term stability and growth within communities.

3DCP options are rapidly becoming a tool used by modern construction companies. Source: guteksk7/Adobe Stock 3DCP options are rapidly becoming a tool used by modern construction companies. Source: guteksk7/Adobe Stock

Challenges and limitations

Despite its numerous advantages, challenges remain that hinder widespread endorsement. There are huge financial barriers associated with purchasing industrial-sized 3D printers at a price point between $20,000 and $100,000. The ongoing operational and maintenance costs of these sophisticated machines add to the overall expense, making the integration of such technology particularly daunting for smaller construction firms and deterring larger companies from fully committing to it on a significant scale.

The reality is that there is a shortage of skilled labor to operate such machines. There is a growing demand for professionals proficient in designing computer models, operating advanced machinery, and performing maintenance on these complex systems. Without adequate training programs and education, the industry faces a skills gap that hinders the effective use of 3DCP.

Regulatory challenges also pose obstacles. The lack of clear government regulations creates 3DCP hurdles that can delay project approvals and implementation. Each municipality must update building codes and create guidelines for buildability and performance, a complex and time-consuming process.

Future prospects

The future of printed housing looks encouraging. A 1,40 sq ft house — complete with three bedrooms, two baths and a two-car garage in Riverhead, New York, was listed on Zillow for $299,999. ICON, a 3D-printing construction company, said it can produce a 600 to 800 sq ft economy-sized building for as low as $4,000. On the other end of the market, luxury models can exceed $1 million, demonstrating the versatility of 3DCP to cater to all economic strata.

New materials, upgrades to printer technology and automation are all contributing to a more efficient and effective method of 3DCP. Researchers are currently exploring the use of new materials such as wood and bioplastics. One of the most exciting developments in 3D printing technology is the ability to print entire houses in a single day. This has been made possible by the development of hardware and software that can print at a faster rate in hard-to-reach areas or disaster zones.

Looking ahead, the development of fully integrated smart cities where housing is equipped with advanced technologies could revolutionize urban living. Incorporating IoT sensors and AI algorithms into these structures will allow for real-time monitoring and optimization of central systems like HVAC, network connections and communication. While detecting and correcting malfunctions and outages in real-time, they can enhance sustainability and further promote economic viability for millions.

Conclusion

There is enormous potential for 3DCP. As its mechanics develop and communities adapt, the vision of a universally accessible, eco-friendly housing framework becomes increasingly attainable. This new era will be disruptive in enormously beneficial ways, where social, economic and environmental challenges may fade. As a key disruptor to the construction industry, there may just be scalable solutions to housing shortages while minimizing environmental impact. We are entering the era of one house for every global citizen who needs one, achieving the dream of universal housing for all.

About the author

Emily Main holds a J.D. in Compliance Law and a BS in Telecommunications. With extensive experience in the intersection of technology and law, Main has contributed to numerous publications and conferences, exploring technical challenges, innovations, trends and applications. Passionate about communication and networking, she is dedicated to sharing the latest advances in the field with a professional engineering audience through engaging and informative articles.

To contact the author of this article, email GlobalSpecEditors@globalspec.com


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