3D Printing in Construction: Innovation, Promises, and Early Concrete Achievements

3D printing (or additive manufacturing) is profoundly transforming the construction sector. Long confined to industrial prototyping or research architecture, it is now emerging as a practical alternative for designing and building full-scale structures more quickly, with less waste, and sometimes at a lower cost.

Unlike traditional techniques, this technology follows a reversed logic: it prints layer by layer from a digital file, with no formwork or complex assembly. The printers typically use concrete, clay, or earth-based mixtures. This approach allows for freer forms, reduces wasted materials, and paves the way for standardizing structures without standardizing shape.

The Promises of Additive Construction

Researchers from Bauhaus University and the Karlsruhe University of Applied Sciences (Placzek & Schwerdtner, 2024) identified over 204 3D-printed building projects worldwide between 2013 and 2023. This rapid expansion is explained by several factors:

• Time savings: Walls printed in a matter of hours or days, with no pauses or loss of pace.

• Less labor: Printers can operate with a reduced team.

• Less waste: Additive manufacturing uses only the exact amount of material needed.

• Architectural flexibility: Organic forms, arches, and curves that are difficult or expensive to achieve with traditional masonry.

  
  

The Largest 3D-Printed Building in Europe: Wave House in Heidelberg, Germany

The Wave House project in Heidelberg, Germany, currently represents the largest 3D-printed building in Europe. This 600 m² data center, designed by PERI 3D Construction in collaboration with KRAUSGRUPPE, uses 3D printing to create complex concrete structures that would be difficult to achieve with traditional construction methods. The construction of this building was made possible thanks to the COBOD BOD2 printer, a large-scale machine capable of extruding concrete walls at an industrial scale.

The use of 3D printing for this project allowed for a reduction in labor costs and an acceleration of the construction process while offering unprecedented architectural flexibility. The building, which features undulating walls and a robust structure, not only demonstrates the feasibility of 3D printing for large-scale construction but also reflects the building industry's commitment to faster and more sustainable construction.

A 3D-Printed Administrative Office in Dubai: An Iconic Innovation Project

In 2019, the Dubai Municipality inaugurated one of the largest 3D printed buildings in the world, a 640 m² administrative office. This project reflects the emirate’s ambitions, which aim for 25% of new constructions to be 3D-printed by 2030.

The building was made possible by a large-scale printer developed by Apis Cor. This machine allowed on-site extrusion of fast curing fiber reinforced concrete in a continuous process without relying on prefabricated elements. The structure was printed wall by wall over two levels, with remarkable precision and consistency.

This project demonstrates the technical and economic feasibility of large scale 3D printing, offering significant savings in labor costs and construction time.

The Largest 3D-Printed Building in the World: Printed Farms in Florida, USA

In June 2023, Printed Farms and COBOD announced the completion of what is claimed to be the largest 3D-printed building in the world, located in Wellington, Florida. This structure, a luxury stable, covers a total area of 10,105 square feet (approximately 939 m²), nearly 50% larger than the previous record holder in the Middle East.

Although its height of 4 meters is modest, its floor area makes it a remarkable achievement, especially considering the dimensions of the printer used. The building was designed to withstand Florida’s extreme weather conditions, including hurricanes and tropical storms. The 3D-printed walls create a cavity and an air space, allowing natural cooling of the structure.

3D-Printed Pedestrian Bridge (Nijmegen, Netherlands): Infrastructure Innovation in Concrete

The 3D printed pedestrian bridge in Nijmegen, developed through a collaboration between Rijkswaterstaat, Eindhoven University of Technology, and construction firms BAM and Weber Beamix, represents a major leap in additive manufacturing for infrastructure. Officially inaugurated in 2021, the bridge spans 29 meters, making it the longest 3D printed concrete pedestrian bridge in the world.

Built using a fully automated concrete printing system, the structure showcases a material-efficient design enabled by parametric modeling and structural optimization. Instead of traditional formwork, the bridge was printed layer by layer using a custom concrete mix, precisely extruded where needed, significantly reducing material waste and environmental impact.

This project exemplifies the potential of 3D printing in civil engineering by reducing construction time, improving sustainability, and demonstrating the structural viability of large-scale printed elements. It marks a shift in how infrastructure can be designed and built through digital fabrication.

3D-Printed Earthen Pavilion for Expo Osaka 2025

For the 2025 World Expo in Osaka, an innovative pavilion was designed by Aki Hamada in collaboration with 3D WASP, a leading player in 3D printing. This pavilion is made of raw earth, a local and biodegradable material, 3D printed on site, a first for a world exposition. The project aims to showcase the possibilities of 3D printing with natural materials to create sustainable and harmonious structures.

Construction was carried out using the Crane WASP, a robotic 3D printer capable of extruding natural earth mixtures and other local resources to shape organic and complex forms. The pavilion will serve as a relaxation and resting area for visitors, integrating architectural elements inspired by nature and the local environment. It highlights Expo Osaka 2025’s commitment to sustainability and ecological innovation in architecture.

A Promising but Regulated Future

Despite the many examples, 3D printing in construction is still in its early stages. Numerous challenges remain:

• Building codes and insurance frameworks are not fully adapted

• Long-term durability of materials and structures

• Integration of technical networks (water, electricity, ventilation)

• High cost of machines and their maintenance

  
  

Still, applications are rapidly expanding: emergency housing, eco-friendly dwellings, construction in remote areas, and even space projects (like NASA’s initiatives for the Moon or Mars). The technology is modular, customizable, and scalable.

Conclusion

3D printing in construction does not yet replace traditional methods, but it opens a new horizon for sustainable architecture and building. By enabling the printing of sturdy, low-cost housing with less labor and often using local materials, it offers a solution well-suited to the challenges of the 21st century: rapid urbanization and ecological transition.

Real-world cases like Nijmegen Bridge, Dubai, or the German project show that this technology is no longer purely experimental. It is already in use across a wide variety of contexts and could soon become standard for certain types of construction.

Sources

[1] Placzek, G., & Schwerdtner, A. (2024). A Global Snapshot of 3D-Printed Buildings: Uncovering    Robotic-Oriented Fabrication Strategies, Buildings. https://www.researchgate.net/publication/385325078_A_Global_Snapshot_of_3D-Printed_Buildings_Uncovering_Robotic-Oriented_Fabrication_Strategies

[2] Additive manufacturing in construction: A review on processes and materials, ScienceDirect https://www.sciencedirect.com/science/article/pii/S2214860419309029?utm_source=chatgpt.com

[3] Pedestrian Bridge  Nijmegen,Netherlands https://3dprintingindustry.com/news/worlds-longest-3d-printed-concrete-pedestrian-bridge-unveiled-in-nijmegen-195951/

[4] 3D WASP. (2025, 30 avril). A 3D printed earthen rest facility for Expo Osaka 2025. https://www.3dwasp.com/en/3d-printed-earthen-rest-facility-for-expo-osaka-2025/

[5] COBOD. (2023, 4 mai). Europe’s largest 3D printed building is being constructed in Germany. https://cobod.com/fr/le-plus-grand-batiment-imprime-en-3d-deurope-est-en-cours-de-construction-en-allemagne/

[6] Eco-Friendly 3D Printed House Uses Soil, Not Cement. Tom’s Hardware (2025). https://www.tomshardware.com/3d-printing/eco-friendly-3d-printed-house-uses-soil-not-cement-building-still-scores-top-earthquake-resistance-rating

[7] 3Dnatives. (2023, 20 juin). World's largest 3D-printed building erected in Florida. 3Dnatives. https://www.3dnatives.com/en/worlds-largest-3d-printed-building-erected-in-florida-200620236/

https://www.axios.com/2023/07/14/florida-barn-3d-printed-building-emissions

[8] LECTURA Press. (2019). Collaborative project with Dubai Municipality https://lectura.press/en/article/collaborative-project-with-dubai-municipality/49585