From prototypes to complete wall systems
The construction industry is experiencing a paradigm shift with additive manufacturing processes. What once began in FabLabs and research laboratories is now becoming a reality on large construction sites: 3D printers build prototypes, façade elements and even complete walls in just a few days. This process saves material, reduces waste and opens up completely new design freedom for architects, engineers and builders. In the following, we will show you practical examples, explain the most important technologies and give you tips on how you can realize sustainable building elements with 3D printing.
Additive processes at a glance: Technologies and materials
- Extrusion-based concrete 3D printing
In extrusion printing, a specially developed concrete mix is pressed out of a nozzle layer by layer. Advantages: high printing speed, good printing stability and low material loss. Post-processing steps such as smoothing or plastering are minimal thanks to the uniform layer structure. - Powder bed process for plastic and mineral building materials
In powder bed processes, a powder application first distributes fine synthetic resin or cement powder, which is then solidified locally by emitters. This allows complex, fine-dimensional structures to be created – ideal for filigree façade elements or thermal insulation profiles with variable porosity. - Sustainable material innovations
- Recycled concrete: aggregates from deconstruction are used as aggregate to reduce the carbon footprint.
- Bio-based plastics: Lignin- or PLA-based polymers guarantee good printability and subsequent recycling.
- Geopolymers: Natural, mineral binders that do not require cement and offer high resistance to weathering.
Practical examples & success factors
Prototype construction and test modules
Research institutes and start-ups initially print small components to test material properties, printing parameters and statics. These prototypes help to further develop the formulation and meet construction standards
Complete wall systems
In the Netherlands and China, there are now entire test houses whose walls were created using 3D printers. A printing project in Shenzhen (2024) delivered a single-storey wall system with integrated insulation channels – in just 48 hours. The accuracy was less than one millimeter, meaning that drywall construction work was almost eliminated.
Integration into the construction site
- Digital twin & BIM: 3D print data is seamlessly fed into BIM models. This allows components to be located and parameterized immediately.
- Logistics optimization: Mobile printer vehicles minimize transport routes and storage space. Freshly printed elements go directly from the machine to assembly.
- IT infrastructure & automation: Our sister company B3YOND‑IT supports you in connecting your print data to the cloud, monitoring print parameters in real time and securing your digital workflows
Sustainability and outlook
The biggest advantage of 3D concrete printing lies in its material efficiency: material is only used where loads actually occur. Hollow profiles and variable wall thicknesses reduce consumption by up to 60% compared to conventional formwork. In addition, the pressure layer-based structure allows cables and insulation materials to be embedded without additional work steps
Looking to the future, the following trends will be decisive:
- Multi-material printing: switching between concrete, plastic and insulating materials in a single process.
- AI-supported print optimization: Machine learning models that adjust print parameters in real time to further improve impact resistance, adhesion and appearance.
- Circular building: deconstruction concepts in which additively manufactured elements are reprocessed or recycled at the end of their useful life.
3XPERTS & B3YOND-IT: Your partner for 3D printing construction
At 3XPERTS, we support you from prototype development to series production of your wall elements. Together with our IT partner B3YOND-IT, we ensure a robust infrastructure, secure cloud processes and tailor-made automation solutions. Contact us at info@3xperts.com or use our contact form on 3XPERTS.com to experience the future of construction today.