“Building the Future: Exploring the Potential of 3D Printing in Construction”

• Himanshu Patni
• June 1, 2023
• ADVANCE MATERIALS & CHEMICALS, BLOG, Chemical
• 3D Printing in Construction, 3D Printing in Construction Analysis, 3D Printing in Construction Forecast, 3D Printing in Construction Growth, 3D Printing in Construction Share, 3D Printing in Construction Size, 3D Printing in Construction Trends
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Making three-dimensional solid products from a computer-aided digital file is known as 3D printing, also known as additive manufacturing.

In the beginning, the term “3D printing” refers to the process of depositing layers upon layers of a binder material onto a powder bed using inkjet printer heads. However, the definition now encompasses a wider range of additive manufacturing processes, including selective laser melting and electron-beam additive manufacturing.

Early in the 1980s, Japanese inventor Hideo Kodama developed two additive techniques for creating three-dimensional plastic models, which gave rise to the idea of additive manufacturing. He created 3D printed structures using a photo-hardening thermoset polymer.

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What are 3D printers?

To put it simply, 3D printers employ CAD (Computer Aided Design) that is powered by 3D technology to produce 3D items from a variety of materials, including molten plastic, powder, and concrete. A 3D printed home can be created using a variety of 3D printers, ranging in size and design from little building models that fit on a tabletop. 3D printers come in three basic categories, and they all operate somewhat differently.

Types of 3D printers

·        Stereolithographic (SLA printers) –  3D printers that use stereolithography (SLA) technology can turn liquid resin into plastic.

·        Selective laser sintering (SLS printers) – SLS printers (selective laser sintering): These printers sinter polymer powder particles into solid structures using a laser.

·        Fused deposition modeling (FDM printers) – These printers create layered things by releasing molten thermoplastic filaments through a heated nozzle. The 3D construction approach is where these printers are most frequently employed.

How does 3D printing apply to the building industry?

 Since the 1980s, several questions have been raised about 3D printing technology. The advancement of the method itself, which enables the construction of three-dimensional objects by superimposing successive layers of material, has, however, given it increased relevance. This method of building is very adaptable and can be used to build specific project elements as well as a variety of complex structures in their entirety, including houses or living spaces, offices, bridges, walls, modular structures, reinforcement moulds, columns, urban furniture, and even decorative elements.

A significant portion of the knowledge required to implement this technology in construction comes from the design phase. The integration of 3D printing technology is less difficult because the sector already has expertise with computer-aided manufacturing and BIM (Building Information Modeling) is flourishing in the building business. A 3D printer obtains the necessary information from a CAD or BIM programme, and the machines start to overlay material levels in accordance with the signals. This can be done using a variety of materials, the most popular of which being a blend of sand, fibre, geo polymers, and concrete.

According to a survey by Research and Markets, 3D printing has advanced in such a positive way over the past ten years that its market value in the construction industry is predicted to reach up to USD $ 1,034,096.7 thousand by 2028. This increases its compound annual growth rate from 2021 to 2028 by 91.5%.

3D printing in construction worldwide

Construction and better infrastructure are becoming more and more in demand, particularly in big cities. Compared to 1800, when only 3% of the population lived in cities, there were 15% more people living in cities by 1900. By 2050, the World Economic Forum projects that two-thirds of the world’s population would reside in major cities, up from the current 55% share.

Numerous government initiatives that support the use of 3D printing are currently under built on a global basis. Dubai, where 25% of buildings must be created with 3D printing technology by 2030, is one of the cities that chooses to lead the pack in this race.

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Available technologies for 3D printing in construction

Robotic arm extruders

Robotic arm extruders are popular among the 3D printing technologies now on the market. This technique is called contour crafting. It functions similarly to a desktop FDM 3D printer. The rails are set up in a pattern that allows the robotic arm to pass through them layer by layer while extruding concrete that is coming out of the nozzle. This method of 3D printing XL buildings is the most popular.

3D printing with sand

The industrial 3D printing processes like SLS (Selective Laser Sintering) and Jet Fusion are comparable to the 3D procedure that is explained here. The first to put it to the test with his D-Shape 3D printer was Italian architect Enrico Dini. Before cementing the construction’s shape using a binder, the machine coats the surface with sand powder. This is comparable to the operation of a metal 3D printer.

Metal technology

WAAM (Wire Arc Additive Manufacturing) was developed by Dutch startup MX3D for more heavily stressed structures like bridges. An industrial robot and a welding machine were combined by the company, and the result was a 3D printer that operated on software that was especially created for the task. The robot has a 6-axes configuration for 3D printing metal structures.

Benefits of 3D printing for building

·        Enhanced design flexibility – The creation of complex designs is a significant architectural difficulty that 3D printing can address. Computer programmes that can be programmed to carry out complex and difficult designs are used by building 3D printers.

·        Adaptation to BIM – BIM Through the use of 3D technology, building information modelling has transformed building design. It displays images of enormous buildings and structures before they are really constructed. This breakthrough can be advanced by construction 3D printing by integrating with BIM and executing complex designs with almost perfect accuracy.

·       Cut down on human error – The foundation of 3D printing is pre-programmed automated operation free from human influence. This essentially eliminates mistakes brought on by people. Additionally, 3D printers don’t require much human oversight.

·        Aid to green building construction – The most popular type of building is quickly shifting toward being green. Construction companies have started using green construction methods as a result of growing climate change awareness. By using discarded and repurposed construction materials to produce 3D printed structures, 3D printers can play a significant part in this endeavor.

3D printed constructions’ drawbacks

·        High Power Consumption – More electricity is used by 3D printers than by any other traditional construction technique. In addition to the environmental cost of producing electricity with such high capacity, meeting such a big demand for power is expensive.

·        3D printers are expensive – It is not now economically feasible to use 3D printing because the technology is still in its infancy. The initial investment required to set up a 3D printing facility for building structures is significant, and in its current configuration it is too expensive to implement in the primary construction sector.

·   Scarcity of materials – Regular building supplies cannot be utilized with 3D printers. Specialized materials, which are not yet widely used, are required by a 3D printer. Due to the material’s significant cost increase because of scarcity and the pricey printer, it is not feasible to employ it for large-scale building.

Market size for 3D printing in construction

1.     3D printed family home in Moscow

A 3D printed home was constructed in Moscow by the American technology company Apis Cor. The house is the first of its kind to use automation in homebuilding and is identical to any other concrete structure. The total cost of construction was less than $10,000.

2.     World’s largest 3D printed building in Dubai

Recently, there have been new technology advances in the Middle East, especially in the UAE. The Guinness Book of World Records has already verified Emirates Tower Complex’s claim that it is the world’s largest 3D-printed building, continuing this trend in 3D printing. The two-story building, which was constructed by Apis Cor, has a surface area of 640 m2 and a height of 9.5 m.

3.     3D Printed Houses in North America and the Caribbean

Worldwide communities and nonprofit organizations are employing concrete 3D printing technology to solve the affordable housing crisis. For example, New Story, a nonprofit organization, constructed Mexico’s first 3D-printed home in a record-breaking 24 hours. Since then, the company has constructed neighborhoods with 2,000 homes, all of which were constructed using the 3D printing construction technique.

The Future

A growing number of projects throughout the world show that 3D printing structures has the potential to be a revolutionary, industry-changing technology that will address several problems now plaguing the construction sector. The level of ambition is enormous; for instance, 25% of new structures in Dubai are expected to be 3D-printed by 2030. To put it mildly, the use of 3D printing in the construction sector has a promising future.

Conclusion

The building industry is poised for innovation, despite the fact that 3D printing still has many long-standing problems. Traditional construction methods can be inefficient, costly, time-consuming, and environmentally damaging. Thanks to the accuracy, speed, and dependability of 3D printing, civil engineers have numerous opportunities to address these challenges and perhaps make it easier and more affordable to design and construct livable structures.

Author: Sonu Kumar Sah

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