Design and Construction, FM Perspectives, Green Building, Sustainability/Business Continuity, Training

Is 3D Printing the Future of Facility Construction?

Editor’s note: FM Perspectives are industry op-eds. The views expressed are the authors’ and do not necessarily reflect those of Facilities Management Advisor.

The construction industry stands at a transformative juncture. After years of technological advancements in sectors such as energy, healthcare, and telecommunications, construction is finally getting the innovative lift it deserves. At the heart of this evolution is 3D concrete printing (3DCP), a technology with the potential to solve long-standing industry challenges related to labor shortages, cost inflation, and sustainability.

Alquist 3D recently completed a 3D-printed store addition for retail giant Walmart.

Over the past year, this technology has demonstrated remarkable developments in making 3DCP a practical solution for real-world residential and commercial construction. For example, Walmart recently embraced 3DCP for a store expansion in Tennessee.

Looking ahead to the next five to 10 years, there are both significant challenges and exciting opportunities that will shape the future of this industry.

Current Challenges in 3D Concrete Printing

We must remember that for as fast as technology progresses, we have only been 3D printing with concrete in a practical manner in the U.S. for about 6 years, and there are only a handful of companies doing this. Therefore, 3DCP offers innovative solutions, but as an emerging industry, it faces a suite of practical challenges that we are just beginning to learn and overcome. We can break these down into four categories:

  • Robotics
  • Material
  • Training/Experience
  • Non-Residential/Commercial Printing

Robotics

There are two major types of bots, gantry and robotic arms. Gantry machines have been the most favored and sold over the past five years, but even as new machines hit the market (the trend is turning to hydraulic, tilt up gantries on rail systems) these machines are largely overkill for the bulk of the 3D residential market. Most printed homes tend to be under 1,800 square feet. While these machines perform well, they are cumbersome to set up and calibrate, expensive to purchase and transport, and require significant training. My take is that these machines will come back into fashion once the industry goes further vertical, but until then, gantries are a bit much for smaller homes. That said, when printing a row of units, gantry printers can be effective.

Robotic arms have limitations as well, but when it comes to speed, price, and efficiency, I find arms to be the clear choice as the market stands today. Arms come in several different styles: pedestal for training purposes, rail systems for small-scale structures, and even on tank treads and full-scale chassis. Many new arms can stretch to print 20 feet high and span that length with attachments but sometimes require a movement or two depending on the design of the print.

Walmart project video courtesy of Alquist 3D

Outside of the printers themselves, more progress is needed on the pump systems. There are multiple types of pumps on the market, but where robot printers are at 3.0 stage today, I feel pump systems are at negative 10. These machines are certainly not the shiny, sexy objects that the printers are, but they are vital to the industry, and more attention is needed to create stronger pumps that are accessible to a variety of printer models to increase speed and cut costs.

Material

Another challenge lies in material limitations. Current 3D printing mixes are often tailored for specific climates and applications, limiting their versatility. Developing universal, adaptable concrete formulas that withstand a range of environmental conditions—from humid coasts to dry deserts—remains a complex task. Additionally, printing large-scale structures requires advanced, durable hardware that can handle repeated cycles of high-intensity work. The durability of 3D printers and their capacity for multi-material integration will need continuous improvement to meet the growing demands of the industry.

By far the biggest game-changer for the 3DCP industry is the material. Similar to desktop printers which have all become ubiquitous today, the “ink” carries more variables. Simply put, the gold standard for 3DCP material is one that costs below $300/cubic yard, hits at least 5,000 PSI, is carbon negative, and can be made locally in your own backyard. The race is on to create this material in the commercial sector.

Training/Experience

We do not yet live in a world where a 3DCP advert for hiring yields hundreds of resumes. Additionally, it is time consuming and expensive to train new teams on the job site. Finally, and this is by far the most overlooked factor in the 3DCP world, this technology lends itself perfectly as a gateway for workforce development.

The quickest path to advancing the industry is by producing more 3D-printed structures, which require a well-trained workforce. A new 3DCP curriculum launched last summer at a community college in Colorado has already attracted over 100 students, with plans to expand similar programs nationwide by collaborating with other educational institutions.

Many young people today aren’t drawn to traditional construction roles, but they are excited by the idea of working with advanced technology like giant robots. This technology can be a powerful tool to attract younger generations into the trades through specialized certificate programs. It also offers an opportunity to engage underrepresented groups in construction, including women and people of color, inspiring them to explore careers in the industry.

Non-Residential/Commercial Printing

Printing a house is by far the coolest thing you can do today. However, as the industry struggles to lower costs and truly get below traditional methods, we can hone our skills by printing projects that are, today, potentially profitable and less expensive than typical builds. Infrastructure like curbs, planters, retaining walls, landscape architecture, highways dividers and barriers, drainage, etc., are being printed off-site, in controlled environments. More municipalities should work with their local 3DCP companies (should they be there) to provide these possibly cost-saving and greener products now, which will also help refine the printing process and gain valuable experience for a future workforce.

Then there are the overarching challenges that any emerging industry must address. One of the most pressing issues is the lack of established building codes and regulatory frameworks. Traditional construction has centuries of codified standards and expectations, whereas 3DCP lacks uniform codes, creating uncertainty among regulators and builders. For 3DCP to become mainstream, local, state, and federal authorities must align on a clear set of standards for 3D-printed structures, encompassing safety, quality, and performance.

Overcoming These Challenges

The path forward for advancing 3DCP requires collaboration across the industry, investment in research, and the formation of strategic partnerships. Prioritizing work with universities, material scientists, and construction experts has proven essential to addressing key challenges. Collaborative efforts with organizations focused on affordable housing have showcased the advantages of 3DCP, but have yet to reach their goal of faster construction and cost efficiency.

We must remember that we are a new, small industry where competition is rarely prevalent now. Collaboration will only lift all boats. ASTM International and others have been working towards this goal for years. These initiatives also demonstrate the potential to influence local governments to adopt provisional building codes tailored to 3D-printed structures when the right stakeholders are involved.

On the materials side, significant investment has been made in developing custom concrete mixes designed to improve printability and durability across various climates. Partnerships with sustainable material providers are also being explored to integrate recycled or renewable resources, with the goal of making 3DCP a more environmentally friendly solution. Recognizing the need to adapt to different conditions, ongoing research and real-world testing in diverse locations remain priorities for refining material formulas and advancing the technology. And of course, more investment from the public sector to realize these materials would be the fastest game-changer.

To address the skills gap, Aims Community College in Greeley, Colo., launched a specialized training program to equip local workers with the expertise needed for 3DCP projects. This initiative not only supports workforce development but also creates new job opportunities, ensuring that projects are both technologically innovative and socially beneficial. As educational institutions increasingly integrate 3DCP into their engineering and architecture programs, a stronger pipeline of skilled professionals is expected to emerge, ready to propel the technology into the future.

Bigger-Picture Challenges for the Industry

As the 3DCP industry grows, it faces significant challenges. One major concern is the environmental impact of scaling concrete use, given that cement production is a major contributor to CO₂ emissions. While 3DCP offers the advantage of reducing material waste compared to traditional construction methods, the industry must prioritize the development of materials with lower carbon footprints. Solutions like carbon-neutral or even carbon-negative concrete formulas will be critical for achieving long-term sustainability, ensuring that innovation is paired with environmental responsibility.

Another broad challenge involves public perception. Despite its potential, some people remain hesitant about living or working in a “printed” building, as the term may conjure up concerns about fragility or impermanence. Addressing these misconceptions will require educating the public on the safety, durability, and benefits of 3D-printed structures. Efforts to normalize 3DCP will depend on building projects that meet or exceed traditional standards for strength and longevity, alongside fostering trust through transparency, community involvement, and consistently demonstrating quality.

And of course, at the end of the day, the best way to normalize 3DCP is simply more 3D homes and structures being printed and lived in/worked in. This process is well on its way, but more research and development in the public sector could turbocharge the industry.

Leading the Way With 3D Concrete Printing

Over the past year, considerable progress has been made in 3D concrete printing, from creating the first 3D-printed homes in Virginia to tackling commercial projects that highlight the adaptability of this technology. Each completed project demonstrates the capability to address diverse needs, whether by delivering housing or constructing resilient commercial spaces. These achievements underscore the potential for this technology to lead as both an industry innovator and a practical solution provider.

A commitment to local economies and sustainable building practices distinguishes this approach. The goal is not just to build faster or cheaper but to create lasting, meaningful impacts in the communities served. The vision extends beyond cutting costs or reducing timelines; it is about reshaping construction to prioritize affordability, sustainability, and community benefits. Staying at the forefront involves not only advancing technology but also building partnerships with municipalities, NGOs, and private organizations that share a vision of a sustainable and accessible future.

Printing a home in a community is great, but we need a full economic ecosystem to realize ongoing results. This means a local school needs to train a workforce, a local GC or developer needs to hire the trained workers, and the local municipality needs to partner with the GC for infrastructure projects that can sustain the company while it scales up to significant numbers of residential and/or commercial structures. This is the complete ecosystem. Rinse and repeat everywhere.

The Future: How to Stand Out as a Leader

In the next five to 10 years, 3DCP will become more competitive, with more companies entering the field. To stand out, we must remain focused on a multi-pronged strategy:

  1. Pioneering Sustainable Practices: Sustainability is more than a trend; it’s a requirement for long-term success. By continuing our research into eco-friendly materials and refining our carbon footprint, we aim to lead the way in green construction. We envision a future where all 3DCP projects are carbon-neutral, positioning us as a responsible leader in construction technology.
  2. Expanding Applicability: While residential applications have garnered significant attention, commercial 3DCP offers immense potential. Exploring opportunities in building schools, clinics, and disaster relief shelters should also remain top of mind. These projects not only diversify our portfolio but also prove that 3DCP can serve a wide range of needs, both private and public.
  3. Investing in Education and Workforce Development: To build a resilient, skilled workforce, we are forming partnerships with educational institutions and training programs to equip future professionals with 3DCP expertise. By fostering industry-specific talent, we aim to sustain a skilled labor pool capable of pushing this technology forward.
  4. Enhancing Technological Integration: We are committed to integrating advancements in artificial intelligence and robotics into our 3D printing operations, allowing us to improve speed, efficiency, and precision. In the coming years, we plan to develop fully autonomous construction sites, reducing labor needs further and enabling even greater cost savings.

A Vision for the Future

The future of construction is digital, sustainable, and inclusive, and this transformation is reshaping how communities are built. By focusing on affordable homes, eco-friendly commercial spaces, and resilient infrastructure, the goal is to redefine construction practices. This approach has the potential to not only reduce costs and timelines but also pave the way for a more sustainable and accessible world.

The next decade will undoubtedly bring challenges, but with dedication, innovation, and collaboration, these obstacles can be overcome. This movement is not just about constructing buildings, it’s about shaping the future of construction, one layer at a time. The vision is for 3DCP to transition from being a novel option to a cornerstone of modern architecture, delivering resilience, affordability, and sustainability in every project. The path ahead may be difficult, but the commitment to leading this change remains strong.

Zachary Mannheimer is the founder and chairman of Alquist 3D, a 3D concrete printing construction company.

Leave a Reply

Your email address will not be published. Required fields are marked *