3D concrete printing is emerging as a significant technology for the construction industry in Iowa, particularly through research and innovation initiatives at Iowa State University (ISU). With support and funding from the Iowa Economic Development Authority, ISU has been developing methods to teach 3D concrete printing since 2022, focusing on the material, equipment setup, and the necessary software and hardware.
Shelby Doyle, an associate professor at ISU, leads these efforts, emphasizing the intricacies involved in educating design students about this technology. The university recently collaborated with OPN Architects, a design firm, to create a 3D-printed outdoor seating area outside the newly constructed Rudd Public Library, which was rebuilt after a tornado destroyed the previous structure in December 2021.
This project allowed both ISU and OPN to leverage emerging technologies and blend their expertise, with OPN keen on integrating 3D printing into their workflows. The outdoor seating features seven unique 3D-printed concrete pieces designed for comfort.
While 3D printing is often seen as a quick solution, Gasper, an architectural designer at OPN, notes the labor-intensive process involved. Mixing the concrete, managing the printing process, and resolving issues like clogs or air bubbles requires significant human oversight, suggesting that while automation is involved, it does not replace the need for skilled labor.
The collaboration involved not only the technical aspects but also augmented reality (AR) to visualize designs before execution. This innovative approach allowed for better project planning and execution.
Despite the challenges in shifting heavy 3D-printed pieces, the team persevered, illustrating the evolving nature of construction practices. Doyle highlights the common misconceptions about the 3D printing process, clarifying that it requires considerable knowledge and oversight rather than a mere push of a button.
ISU’s journey into 3D concrete printing reflects broader trends, with others in Iowa, such as Zachary Mannheimer from Alquist 3D, also exploring this space. Alquist 3D recently faced setbacks with a project aimed at building Iowa’s first 3D-printed home but has expanded its operations significantly since its inception in 2020 and is involved in larger projects, including a major addition to a Walmart in Tennessee.
The technology promises a transformation in how structures are designed and built, offering geometrical flexibility and potential reductions in material usage. Experts like Mannheimer are optimistic about the industry’s future, forecasting that 3D printing will become commonplace across job sites in the coming decade.
Challenges remain, particularly around cost and material adherence to building standards, but there’s optimism about its potential applications, particularly in rapid deployment situations like disaster recovery. Future developments may also focus on locally sourced materials to reduce costs and reliance on traditional building methods, further emphasizing the need for continuous innovation in the construction sector.