Integrating 3D Printing In Construction

Abstract

Extrusion-based 3D concrete printing (3DCP) offers significant potential for construction automation, including reduced labor, minimized waste, and enhanced design freedom. However, its transition from proof of concept to scalable deployment is hindered by misalignment between material-machine performance, regulatory compliance, and onsite workflows. This thesis addresses this gap by developing and validating a ThreePillar Integration Framework (Functional, Regulatory, Workflow). Informed by secondary case analysis of four landmark projects (ICON’s House Zero, Winsun Villas, COBOD/Van Wijnen homes, Dubai’s Office of the Future), the framework is demonstrated on a 50 m² gantry-printed wall use case. The Functional Pillar establishes critical parameters, including structural performance targets (≥31 MPa compressive strength, ≥2 MPa interlayer bond, and 2-hour fire resistance), as well as real-time dimensional accuracy (±5 mm), for reliable printing under variable conditions. The Regulatory Pillar defines a structured compliance pathway integrating ICC-ES AC509, ISO/ASTM 52939, comprehensive permitting, digital traceability, and post-approval monitoring. The Workflow Pillar ensures seamless integration into construction through BIM-to-print handoffs, calibrated site protocols, inline quality assurance, and automated error correction. While focused on extrusion methods and secondary data, this framework provides a scalable roadmap for mainstreaming 3DCP in regulated environments and forms a basis for future extensions.