We discover more about 3D printing through five impressive case studies of integration between this cutting-edge technology and architectureMEP Design
New technologies are constantly transforming the way we conceive architecture. Among these, large-scale 3D building printing stands out as one of the most fascinating innovations. Thanks to the use of composite materials, this technology makes it possible to create entire structures or parts of buildings with large-scale 3D printers from a digital model (CAD). Materials such as plastic, concrete, and metal can be “extruded” by advanced machinery and shaped into highly customizable forms.
This technology opens up unprecedented scenarios both in terms of design and construction efficiency. But is 3D printing already a reliable solution, or is it still an experimental technology? And above all, will it really manage to revolutionise the architecture sector? To answer these questions, we analyze five cutting-edge projects — extraordinary examples of integration between architecture and 3D printing. From the striking entrance of the Beyond the Geometry Pavilion, to the MX3D steel bridge, to TECLA’s sustainable housing solutions, we explore how 3D printing is redefining the construction industry and challenging traditional building methods.
PLASTIC
The ‘Beyond the Geometry Pavilion’ (design: Archi-Union Architects, 2021) serves as a gate into the Happy Valley amusement park in Nanjing, China. Its hyperbolic geometries extend 52 metres in length and 26 metres in width. It is composed of a steel skeleton frame clad with more than 4,000 contoured 3D printed plastic panels. These panels were prefabricated remotely in a factory, with printing paths and robot control files managed in real time by one of the design team members located in Malaysia during the pandemic. Each panel is printed in one of six different shades of pink arranged in a random pattern.
SANDSTONE AND PLASTIC
The ‘Smart Slab’ (Digital Building Technologies at ETH Zürich, 2018) is a materially efficient, free-form building element prefabricated using 3D-printed formworks for concrete. It is the main load-bearing horizontal element of a residential unit for four occupants on the Empa and Eawag Campus in Dübendorf, Switzerland. For fabrication, the 78-square-metre prestressed concrete slab was split into eleven 7.4-metre-long segments. Due to the efficient distribution of material in slender ribs, the slab only weighs 15 tonnes. A conventional solid concrete slab for the same scenario would weigh roughly 45 tonnes.
METAL
The MX3D Bridge (design: Joris Laarman Lab, 2021) is a raw steel structure that spans the Oudezijds Achterburgwal canal in Amsterdam’s city centre. A critical part of the project was the extensive testing needed to prove the structural capacity of the 4,500-kilogram structure. The overall mass of the bridge is 7.8 tonnes, of which approximately 4.6 tonnes were printed. The bridge was printed in four main pieces, plus the four corner swirls, which were then manually welded together. Printing was carried out using a 6-axis ABB industrial robot fitted with a MIG welding machine and controlled using MX3D’s software.
CERAMIC
This façade of a boutique on Amsterdam’s chic P.C. Hooftstraat is composed of 3D printed ceramic tiles, hence the name: ‘Ceramic House’ (architect: Studio RAP, 2023). By integrating advanced methods of ceramic 3D printing, algorithmic design, and artisanal glazing, Studio RAP generated ornamental ceramics fit for the twenty-first century. The façade of the higher floors is composed of 3D printed bricks glazed in three different shades of red. This algorithmically-derived ornamental façade is inspired by garment knitting crafts, and integrating pattern, relief, and colouration results in an exciting design language.
EARTH
TECLA (Technology and Clay) is a circular, low-carbon housing model that brings together research on vernacular construction, the study of bioclimatic principles, and the use of natural and local materials (design: Mario Cucinella Architects, 2021). The new technology applied here uses two synchronised printer arms simultaneously, with their movements optimised by the company’s software. The resulting form consists of two dome-shaped, open-topped volumes. The ribs on the outer surface of the envelope provide self-shading for cooling. They are also hollow to allow air through to naturally ventilate the structure.
It is impossible to deny: 3D printing is causing a genuine revolution in the concept of architectural design. First of all, the use of 3D printing fits perfectly into contemporary design contexts, which place design flexibility and waste reduction at their core. Moreover, 3D technology drives a rethinking of construction processes: it enables the creation of efficient, highly customizable structures in which aesthetics and functionality are equally valued. In conclusion, the integration of 3D printing into construction is an innovation that, if implemented intelligently and sustainably, will certainly contribute to the creation of spaces capable of meeting the new demands of modern building practices.
Alberto Sacchetto
Alberto Sacchetto is an architect with extensive experience in the design and construction of residential and commercial buildings, with particular expertise in the hospitality and wellness sectors. A graduate in Architecture from the Politecnico of Milan, he has developed strong skills in integrating structural, MEP, and architectural solutions, with a focus on energy efficiency, sustainability, and harmony between form and function.
Over the course of his career, he has worked on numerous complex projects in various countries, combining technical knowledge with a strong aesthetic, and always with attention to detail. Passionate about new technologies and innovation, Alberto Sacchetto is constantly pursuing design solutions that enhance the performance of buildings and the quality of life of their users.
