In a decade, 3D printing has already innovated several industries, from medical implants to engineering, to aviation. The technology is achieving the unthinkable in construction such as 3D printing a house in under 24 hours. In Austin, two 3D-printed homes at the East 17th Street Residences development were sold in March and the two others in the development are on the market.

The 3D industry is projected to grow to over a $30 billion annually by 2024, with much of that boom projected to be in construction.  While much of the past growth of 3D printing has not been in large commercial construction project, it has already found applications in certain civil improvements. Completed in October 2018, the world’s largest 3D steel bridge was constructed in Amsterdam.  In 2019, the world’s longest 3D bridge was constructed in China using two robotic arms to significantly reduce manpower costs.  In January of 2019, the US Marines began using 3D technology to construct footbridges in California.

As a concept, 3D printing is not new – it was first developed in the 1980s. However, only in the last decade has the technology improved enough (and the costs declined sufficiently) for it to become mainstream.  3D printers are not unlike your desktop inkjet printer. A software program instructs the printer about the dimensions of the end product. The printer then injects material on a platform according to that plan. 3D printers often use liquid metals, plastics, cement and a variety of other materials which then cool or dry to form a structure. 3D printing in construction can either involve the use of a 3D printer attached to an arm which actively builds a project on-site or the use of printers in a factory which create components of a building project that are assembled later.

Though large-scale projects cannot yet be fully dependent on 3D printing, the technology offers several potential improvements to the construction sector to increase efficiency.

• Waste Reduction

Waste from construction has increasing every year. 3D printing can help reduce the waste from construction of bridges and buildings and can also utilize local materials rather than ordering specific materials from out of state/country suppliers. This may also potentially ease the disruption to the supply chain wrought by the pandemic.

• Quicker Construction

Arguably, 3D printers can work longer hours with greater productivity and fewer mistakes than manual labor.  For instance, machines have built simple shelters in a matter of hours. For more complicated projects, printers can be run for longer than 8-hour shift and since the design is sent to the printer, there are fewer opportunities for misinterpretation of construction documents and non-compliant work.

• Risk Reduction

With construction done by printing machines, health and safety risks can be reduced.  Construction sites are known for higher incidents on site for injury and death. Work injuries and fatalities could be reduced with 3D printing because it makes construction more automated. Robotic construction requires standardized, accurate, and complete digital building information, making a 3D-printing approach more precise and efficient. The possibility of damage to stored materials, assemblies, or work-in-progress is reduced because there is no onsite storage and movement of material.

• Custom Design 

Because 3D printers work by layering up material, they can be programmed to create unusual shapes which would be harder, more expensive and more time consuming to build using traditional techniques.  This will allow architects to create more distinguishable shapes and designs without a significant increase in material or labor costs.

 

For all the potential benefits of 3D printing, there are also some significant drawbacks.

•  Lack of codes and regulations

Companies that produce commonly used codes, such as the International Code Counsel and UL, have struggled to keep pace with the technological advancements of 3D printing.  While some codes were issued in 2020 to specifically address the technology, many uncertainties remain. The use of 3D printing allows for use of new materials that are not as tried-and-true as the conventional building materials of steel, concrete and wood. The composition of 3D printed materials can be changed quickly, affecting material properties and overall durability and performance of the structure.

• Difficulties of integration with other components

3D printing has not yet resolved the issue of integrating the work of different trades.  For instance, if pipes are intended to be installed in a void space between two walls, how is that work integrated in the printing process? One solution is to mount plumbing and HVAC lines externally, though that creates other potential issues including an aesthetic that may not appeal to many.

• Initial Investment Costs

The investment needed to use 3D printing on a large project or widespread basis would be enormous.  Until the technology has established that it can deliver projects with fewer delays and workmanship issues, and at the same or lower cost than conventional methods, construction firms will be hesitant to make the upfront commitment to purchase the equipment.

• Will customers buy in?

3D printed houses, offices, shops or other structures are often impressive to look at, but will customers seek to buy and live in these structures. Many people remain culturally attached to buildings made from wood, stone, bricks, and steel.

• Skilled labor shortage

With the existing labor shortage in the construction sector, 3D printing will require an even more specialized skill set that would have to be chosen from a smaller niche pool of candidates. 3D printing may solve one labor issue—a shortage of manual laborers—by creating another—a shortage of persons trained on designing for, using, and maintaining 3D printers.

As the design and construction industries change, the attorneys in our Austin and Dallas offices are available to help you navigate those changes and answer any questions you may have.

 

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