3D Printing with Eco-Friendly Materials: Reshaping the AEC Industry
3D printing has dramatically changed AEC (architecture, engineering, and construction) workflows by accelerating prototyping and encouraging experimentation with ground-breaking ideas. This new technology has gained significant momentum in the industry, particularly due to its efficiency. However, as more industry decision-makers examine ways to reduce emissions, some are interested in making additional progress by using eco-friendly printing materials.
In this blog, we’ll explore several use cases of 3D printing with eco-friendly materials, highlighting innovative applications that are changing the game by promoting environmentally conscious practices in the AEC industry:
A 3D-printed bridge made with waste materials from stone processing
Tackling Australia’s housing crisis with 3D-printed plastic homes
3D-printed wall and ceiling coverings that reduce humidity levels for optimal indoor comfort
Using nanocellulose as a 3D printing material for green architectural applications
Prototyping a Bridge Made from Marble Processing Waste
Photo from Parametric Architecture
Focusing on ordinarily discarded materials is a creative way to find potential sustainable printing materials. In one example, designers prototyped a self-supported pedestrian bridge inspired by Leonardo Da Vinci.
Those involved received expertise from a startup and demonstrated options for reusing construction waste materials for their 3D-printed items. The bridge’s construction required a large-format 3D printer, and participants divided the structure into 13 variable-layered blocks. Most notably, the bridge’s bricks feature a low-impact mortar composed of 30% waste stone and marble powders with a lime-based binder.
This project is in the early stages, and the next steps include improving the printing process and analyzing the material’s mechanical properties. However, such forward-thinking efforts should encourage construction industry professionals to show similar open-mindedness when exploring ways of using waste rather than discarding it.
Embracing the Circular Economy with Plastic Printing Projects
Many people view waste as inevitable. However, researchers at an Australian university have adopted another perspective. They believe there is no waste, although different materials have purposes that change depending on their usage..
One of the researchers’ priorities is to partner with a 3D printing business to tackle Australia’s housing shortage. As of February 2024, only 0.7% of the nation’s properties were unoccupied. How does this team plan to address that shortage while staying committed to its waste-minimization mindset?
They want to create 3D printing materials with plastic waste, including substituting the virgin materials frequently used when making recycled alternatives. The repurposed option would become central parts of 344-square-foot homes, provided those residences pass structural integrity tests and offer sufficient longevity.
3D printing strategically addresses housing shortages because it is substantially more efficient than traditional construction methods. Additionally, people can combine conventional construction equipment with 3D printers. One option is to mount the printers to tracked aerial lifts, giving workers better access to multistory buildings. Some models have side-reach heights of 50 feet, providing excellent jobsite versatility.
Plastic waste was a prime printing material candidate in Australia because the country sends large amounts of it overseas. However, recent issues concerning other nations’ willingness to accept the waste have created a stockpiling problem, so finding creative ways to reuse it makes sense.
Improving Indoor Comfort with Eco-Friendly Coverings
Building a structure to maximize occupant comfort has always been important, but this may become even more of a concern as climate change causes more temperature extremes.
Researchers recently made a covering for walls and ceilings from mineral waste materials with 3D printers. This innovation temporarily retains moisture, reducing humidity levels. Although many homes and buildings reduce humidity through mechanical ventilation, these options can be costly and are not always energy-efficient.
This indoor covering provides passive dehumidification through a hygroscopic, moisture-binding material that absorbs moisture and releases it once the room is adequately ventilated. The researchers clarified their solution works well for high-traffic rooms with insufficient ventilation.
They chose marble quarry waste as their primary material and used a geopolymer binding agent. Although the binder performs similarly to cement, its CO2 emissions are lower, increasing the material’s overall sustainability.
Fabrication occurs through a binder-jet 3D printing process. Applying the quarry waste in layers before binding it provides flexibility to create various shapes, which could make it easier to implement in buildings receiving eco-friendly upgrades.
Developing a Nanocellulose Hydrogel for Green Architecture
Photo from Chalmers
Since construction is well-established as a high-emissions, material-intensive industry, it’s crucial to explore viable alternatives to support sustainable changes. A notable advancement occurred in February 2024 when a research team used a hydrogel made from nanocellulose and algae in an architectural application for the first time. Although previous efforts have shown the material’s usefulness in biomedicine, this was the first attempt to use it in a dried form for architectural purposes.
Cellulose is a widely available industrial by-product, making it an excellent sustainable 3D printing material candidate. The researchers put the nanocellulose hydrogel into a robotic printer and analyzed its performance as it dried in various shapes and patterns. They envision designers using the dried shapes as foundational parts of various stand-alone products, such as room dividers, window blinds, and wall panels. Alternatively, designers might use the material as a coating or additive for existing materials.
The robotic 3D-printing system only uses air pressure and works at room temperature. That feature makes it less energy-intensive than those requiring heat. However, specific nanocellulose hydrogel properties also make it an energy-saving option. The material retains its shape unless pressure is applied, at which point it becomes liquid, making it ideal for 3D printing. By understanding the material's properties, the team was able to experiment with it while using less energy compared to many traditional processes commonly used in the construction industry.
Advancing the AEC Industry With 3D Printing
These compelling examples highlight why 3D printing is a promising path for achieving greater sustainability in the construction industry. By using 3D printers to create building structures, construction processes can be significantly accelerated, while also reducing transport-related emissions due to the localized nature of printing.
What makes this approach even more eco-friendly is the potential to prioritize greener materials, such as recycled or waste-based materials, which are often overlooked or discarded in traditional construction. By integrating these sustainable materials into the 3D printing process, the industry can further reduce its environmental impact, minimizing waste and conserving resources.
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Author: Jane Marsh is the editor-in-chief at Environment.co, specializing in sustainability, climate change, and renewable energy. In her free time, she enjoys nature trails, eco-friendly DIY projects, and volunteering with environmental groups.
