
12th July, 2024
The Rise of 3D Printing in Construction
Discover how 3D printing in construction revolutionises the industry by enhancing efficiency, reducing costs, and transforming design possibilities.
3D printing in construction, or additive manufacturing, is a groundbreaking technology that creates three-dimensional objects by layering materials based on a digital blueprint. Instead of ink on paper, these large-scale machines use concrete, plastic, or metal to build structures layer by layer. This method diverges from standard modular construction, where materials are cut, shaped, and assembled manually or through machinery.
Types of 3D Printers Used In Construction
These highly specialised machines are capable of handling large-scale projects and robust materials. One common type is gantry-style printers, which operate on a fixed frame, moving the print head along three axes to deposit layers of building materials. The advantage of the gantry printer is that it’s highly precise, thus ideal for building large walls and structural components directly on-site.

Three-axis gantry system of 3D Concrete Printing at Loughborough University, source: ResearchGate
Robotic arm printers, on the other hand, offer more flexibility in movement and can print complex shapes and structures. They rotate and manoeuvre in ways that gantry systems cannot, allowing for more intricate designs and undercuts, which makes them useful in creating custom architectural elements.
A robotic arm 3D printing cement-based materials, source: ReseachGate
Both printer types use specially formulated concrete mixes or other materials suitable for extrusion, designed to set quickly and maintain structural integrity while being laid down layer by layer.
Materials Used in 3D Printing in Construction
The range of materials available for construction 3D printing is evolving rapidly and offers various properties suitable for different applications.
Concrete
Still the most common material used in 3D printing for construction, concrete has been preferred for its standard advantages: strength, durability, and versatility. Specially formulated concrete mixes designed to be extruded through 3D printers contain different additives to enhance properties like quick setting, flowability, and bonding between layers.
Most applications use fibre-reinforced or geopolymer concrete made from industrial waste materials. High-performance concrete engineered for applications that require high strength and durability is also available.
Mortar
Mortar is typically used for smaller-scale or detailed elements. It has a finer texture than concrete and can be modified with additives to improve its properties for 3D printing, such as reducing shrinkage or enhancing bonding.
Plastics
While the word itself might raise some eyebrows, when linked to the technology previously marked as largely environmentally friendly, the plastic used in 3D often complies with conscious production. Polylactic acid (PLA) applied in printing non-structural elements, for instance, is biodegradable and derived from renewable resources such as corn starch or sugarcane. It decomposes naturally.
Acrylonitrile Butadiene Styrene (ABS) and Polyethylene Terephthalate (PET) can be recycled and reincorporated into new projects. Their use in 3D printing for construction promotes a circular economy—a concept aimed at minimising environmental impact by reducing the reliance on virgin materials.
Metals
While less common due to the complexity and cost, metal 3D printing can create strong, intricate structural components.
The materials of choice are stainless steel, aluminium, and titanium.
Composite Materials
Composite materials used for 3D printing in construction include concrete, plastic, and metal blends designed to support or improve specific properties like thermal resistance or hardness.
Bio-Based Masses
These materials are derived from renewable sources and designed to reduce environmental impact. Examples include:
- Mycelium: Fungal material that can be grown into specific shapes. It’s used for insulation or lightweight structural elements.
- Bamboo: Processed and used as a sustainable alternative to traditional building materials.
- Hempcrete: A mixture of hemp fibres and lime, offering good insulation properties and environmental benefits.
Worldwide Examples Pioneering 3D Printing in Construction
The Office of the Future
The official first 3D-printed building in the world is the Office of the Future at Dubai’s Emirates Towers, completed in 2016 as part of a global initiative to position the city as a leader in the 3D printing field by 2030. Its first occupants were the temporary headquarters of the Dubai Future Foundation, succeeded by Dubai’s Museum of the Future.
It’s a single-storey, 2,700-square-foot building that took just 17 days to build. The tool was a 20-foot-tall 3D printer, 120 feet long and 40 feet wide. It layered a unique mix of concrete, fibre-reinforced plastic, and glass fibre-reinforced gypsum.
The printer needed one person on site, a supervisor to ensure everything was functioning correctly.
An 18-person group comprised additional electricians, installers, and mechanical engineers, who completed the job for $140,000 in construction and labour costs.
The Data Collecting MX3D’s Pedestrian Bridge
The world’s first 3D-printed steel bridge over the Oudezijds Achterburgwal canal in Amsterdam was officially opened to public use in July 2021. Designed by Joris Laarman Lab and engineered by Arup, the bridge was created using MX3D’s large-scale, robotic 3D printing technology. Four robots printed the bridge using over 6,000kg of stainless steel, adding layer by layer.
The project’s significance, however, extends beyond exemplifying 3D printing technology. Supported by partners (Autodesk, The Alan Turing Institute, ARUP, University of Twente and FORCE Technology), the bridge and its digital twin contribute valuable data for future smart city developments. They are equipped with numerous sensors to monitor structural health and usage, serving as a living laboratory for exploring advanced manufacturing and IoT systems in urban infrastructure.
Project Milestone
One of the first 3D-printed commercial housing developments, Project Milestone, is also directly connected to the Netherlands. It features multiple 3D-printed houses available in various styles. Located in Eindhoven, this project involves several partners and demonstrates the potential for similar developments within Europe and the UK.
Project Milestone house, source: 3DPrintedHouse
Why the Netherlands?
A country needs a combination of strong government support, advanced research, and strategic partnerships to become a pioneer in 3D printing for construction. The Dutch government actively funds and supports innovation, particularly in sustainable technologies. Leading institutions like TU Delft and the Eindhoven University of Technology conduct cutting-edge research in 3D printing and collaborate closely with industry partners in implementing new technologies, positioning the Netherlands at the forefront of 3D printing advancements.
Additionally, the Netherlands’ focus on sustainability aligns well with the capabilities of 3D printing, which reduces material waste and allows for the use of recycled materials. Dutch companies and institutions collaborate on international projects, leveraging their strong industrial base and expertise in engineering and manufacturing. Projects like the MX3D bridge in Amsterdam showcase the practical applications and benefits of 3D printing, further establishing the country as a leader in this innovative field.
3D Printing In the UK Construction Industry
In the UK, construction has traditionally been conservative and slow to adopt new technologies. However, the tide is turning as the benefits of 3D printing become indisputable. Early adopters in the UK construction industry are leading the charge, revealing reduced costs, faster project timelines, and superb design flexibility.
According to the Expert Market Research report, 3D printing in the UK’s construction and architecture sector is another major trend supporting the market expansion. It involves contour crafting and sand layering, among other processes.
The adoption is gradually gaining momentum, with some notable projects demonstrating the technology’s potential.
Sighthill Pedestrian Bridge
In 2022, the concrete staircase leading to a pedestrian bridge over the M8 motorway in Glasgow became the largest ever 3D-printed structure of its kind in the UK. It was created by BAM and Weber Beamix, printed off-site in the Netherlands and then transported to Scotland for installation.
This method reduced material waste by 40% compared to traditional techniques and minimised the environmental impact. In the words of Ian Steele, BAM Contracts Manager for the footbridge: “The printed element saw us manufacture the stairwells off-site, creating strong, one-of-a-kind structures, all while reducing waste and interaction with weather and other elements which can create hold-ups.“
Building for Humanity Residential Project
Building for Humanity, a housing developer in the UK constructs affordable, carbon-neutral social housing. Their flagship project on Charter Street in Accrington, Lancashire, involves the construction of 46 new homes.
The project aims to create more affordable home ownership and rental properties accessible to all demographics, including singles, low-income families, and homeless veterans. 3D concrete printing will help scale and speed up the building. These high-quality, affordable net-zero homes with a Community Hub on site will be the first in the UK and the largest printed buildings of its kind in Europe.
Source: Building for Humanity
Benefits of 3D Printing for Construction Projects
- Cost reduction: Traditional construction methods produce large amounts of waste and involve high labour costs. 3D printing minimises material waste by using only the necessary amount of material, applied precisely where needed, while automation reduces the need for extensive manual labour.
- Time efficiency: Structures that once took months to build can now be completed in weeks, if not days.
- Environmental impact: 3D printing in construction minimises waste by precisely depositing materials (which are largely recycled or sustainable).
- Customisation and design flexibility: The capacity to create intricate and customised designs enables architects and builders to push the boundaries.
Supported by Digital Supply Chains
The rise of 3D printing on construction sites in the UK represents a significant opportunity for the industry to enhance efficiency, reduce costs, and drive sustainability.
Integrating digital supply chains with 3D printing processes can achieve higher productivity and even more cost-effective outcomes. Book a demo to discover how we can work together to create a more resilient and responsive construction sector ready to meet future challenges.
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