3D Printing: Can imperfect solutions pave the way to a renewable future?

Traditional construction practices are centered around mass production and rely heavily on concrete and steel due to it being the cheapest, fastest, and easiest solution. It is no secret that prioritizing these materials is disastrous for the environment. Within the building sector, embodied carbon - referring to CO2 emissions associated with the entire lifecycle of a project’s material components - is responsible for 13% of global greenhouse gas emissions [i].

In the search for solutions and alternatives to these methods, 3D printing is transforming the way we view each part of the architectural process. It has the potential to revolutionize the way we design and build. Katie Heywood, our very own industrial Ph.D. candidate, is actively making space for novel insights and adaptable methodologies within 3D printing.

Amongst some of the most exciting aspects of 3D printing is the potential to significantly reduce the amount of materials and time needed when building [ii].

Since 3D printing is still in its early stages, concrete is currently the most 3D-printed material in architecture. There are also opportunities arising to print with raw materials such as mud and clay, and as research progresses, these tactics could provide viable alternatives to materials such as concrete.

As the most used substance after water [iii], concrete bears a significant responsibility for negative environmental impacts within the construction industry - because it possesses such unique and desired characteristics, the construction industry relies heavily on the material. Using alternative building methods, such as the 3D printing of concrete, can provide a starting point to decrease the industry's dependence on this material.

The recent IPCC report highlighting “deep, rapid, and sustained greenhouse gas emissions reductions will be needed in all sectors by 2030”[iv], shows we have no time to wait for perfect solutions.  

 “We must work with what we have right now. Is 3-D printed concrete a perfect solution? No. It is not going to solve all our problems, but I do believe it has its place. It is our responsibility to investigate where that place is, and then propose how we can integrate 3D-printed designs into that design process,” Heywood adds.

The what ifs, buts, and maybes 

As 3D printing is still in its early stages, the scale and variety of production can be limited, making it difficult to accurately conduct its life cycle analysis.  To build with 3D printing responsibly, it is important to consider factors such as construction strategy, material choice, printer settings, and boundary conditions. Otherwise, 3D printing risks not being an improved alternative to standard concrete construction.

Katie suggests a balanced viewpoint to the complex discussion, “I think a particularly important way of navigating these issues is through the acknowledgment that we are not where we would like to be, especially in terms of the environmental impacts within the 3D printing process. As an architect, I also think it’s important to keep a dialogue open with other material specialists, and not to close off into the ‘team concrete’ or ‘team timber’, but actually work together to see how our different materials and fabrication strategies could benefit each other.”

Though arguably less enticing at times, a more holistic and balanced approach – one that incorporates a multitude of eco-conscious materials and methods - could be the key to finding an environmentally sustainable path forward.

As part of Katie's research, she has been investigating design strategies for 3DCPs application in different architectural projects. From using 3DCP in a slab structure, to building facades. The focus of her work is not just on lowering the embodied carbon, but also considering other aspects of sustainable design such as circularity, whilst also staying grounded in the 'real world' considerations of installation, time, building regulations, and cost.