Adopting the latest technologies to increase efficiency and reduce costs is essential for most industries to ensure sustained growth. “Real estate has been lagging behind in the adoption of [new] technology and just recently started to explore what these innovative digital solutions can offer,” said Digital Estate, a specialized think tank, in 2021.
Among the most promising technologies is 3D printing. It “is a tool that can redefine the way of building new infrastructure,” said JK Cement, a cement producer in India, in a March blog post. “The potential of 3D printing is immense.”
For Egypt, the technology could prove transformative, given the government’s increased dependence on real estate development to fuel GDP growth. The sector’s contribution will only increase with the government planning to build 24 new cities, plus phase two of the New Administrative Capital.
Machine builder
3D printers can discharge cement and other building materials layer by layer to create three-dimensional structures based on “a digital 3D model design using specialized … software or obtained through 3D scanning technologies,” according to JK Cement’s blog.
An algorithm determines the best layering sequence for the structure. On-site engineers ensure the machines pour the correct amount of cement or other building materials, monitor the 3D printers’ speed, and check that the horizontal layers align correctly.
Those 3D printers can be robotic arms or cranes. The most popular pour cement. Others layer sand and adhesives to harden each layer once it reaches the correct thickness. Some 3D printers layer steel with separate welding machines to bind them together.
Technology of the future
The top benefits of 3D printing over traditional construction are speed and efficiency. “Houses or structures can be built in a few days,” said Xometry, an online marketplace for construction equipment. “3D printers can work through the night … in bad weather, so downtime is minimized.” It also can save time by avoiding human errors and inconsistencies.
The dependence on machines also “reduces labor expenses and overall construction expenditures,” noted JK Cement. Xometry also said “3D technology can take the place of multiple manufacturing machines, so equipment costs will be more reasonable.”
Further reducing costs is that “3D printers use the exact amount of materials … so they typically generate almost zero waste,” noted Indeed, a consultancy. That is significant as construction is “infamous for creating a lot of waste,” said Xomtery.
Additionally, 3D printing can produce “challenging or impossible” shapes for traditional construction methods, noted JK Cement. That flexibility enables “on-site and on-demand construction … where immediate shelter solutions are crucial.”
Meanwhile, “innovative construction-grade materials … can be optimized for strength, durability, and resilience, resulting in robust structures built to withstand diverse environmental conditions,” JK Cement said. Structural alterations can be easily made post-construction and have “minimal impact on cost and require less human effort than traditional construction methods,” noted Xometry.
Lastly, 3D printing makes construction more eco-friendly. In addition to using less material, the machines can be powered by renewable energy, noted JK Cement. Xometry added that 3D printers can use recycled materials, including plastic cans and concrete.
Hard sell?
Emerging economies targeting unemployment could be reluctant to introduce 3D printing in construction, as it dramatically reduces the need for low-skill labor. “3D printing demands an even more specialized set of skills, which could be difficult to source,” said Xometry.
Another challenge is “integrating electrical and mechanical services into 3D-printed structures,” said JK Cement. Also, the technology still needs “controlled settings for optimal operation,” and it can’t handle large-scale projects.
Developers using 3D printing must protect themselves from cyber threats, as hacking could halt construction completely or compromise building integrity, explained JK Cement.
While constructing homes using 3D printers is less expensive than conventional methods, securing and transporting the equipment is expensive. “High investment costs [come from] buying or even renting a 3D printer,” noted Xomerty. “There are also logistical challenges in transporting large 3D printers to work sites. [Also, additional] expenses for [high-quality] materials and maintenance must be taken into account.”
Already here
The UAE was one of the first countries to use 3D printing in construction: the “Office of the Future,” built in 2016 in Dubai, was the third 3D-printed public building in the world.
Also in 2016, Dubai published the Dubai 3D printing strategy, which aims for 25% of buildings in the city to be 3D printed by 2030. “We will raise this percentage with the development of global technology as well as growth of market demand,” Mohammed bin Rashid Al Maktoum, Dubai’s ruler, said when announcing the strategy.
The UAE has a range of 3D-printed structures, from private villas to bus stations to government buildings and mosques. The flagship structure is the new Dubai municipality building, which Guinness World Records said is the world’s biggest 3D-printed structure by volume.
In October, Dubai’s government published the world’s first 3D-printed construction certification system. It assesses the quality of materials and efficiency of manufacturing equipment; sets technical standards; and ensures the efficiency of management systems.
Saudi Arabia started building 3D-printed properties in 2018, with a residential villa that’s open to the public. In the official announcement, the government said 3D printing in construction is part of the “Kingdom’s Vision 2030 and the National Transition 2020 Program.”
The 2019 Building Technology Initiative, which aims to enable 70% of the Saudi population to own homes by 2030, contains incentives for developers using 3D printers.
In March 2023, Guinness World Records said Saudi Arabia had the world’s tallest “on-site 3D-printed building.” Also in March, the country opened the first 3D-printed mosque (Abdul Aziz Abdullah Sharbatly Mosque in Jeddah).
In 2024, Guinness said Qatar has the “tallest freestanding 3D-printed concrete structure (12.4 meters).” It is unusable, as its base measures 13 by 13 meters. Qatar mainly uses 3D printing to build accurate scale models, including the football stadiums used in the 2022 Football World Cup, to test innovative systems.
In March, the Qatari government announced plans to build 14 schools using 3D printing technologies. According to local media, they will open for the 2025-2026 academic year.
Ensuring quality
Xometry said the most significant talking point involving 3D-printed structures is ensuring suitable quality standards. “While 3D printing technology is capable of producing complex structures and customized designs, the final product’s quality can be challenging to maintain,” it said.
In conventional practice, experienced builders can identify defects during construction. With 3D printers, engineers “rely on the printer’s accuracy and precision.” Any problems with design or materials must be identified before the 3D printing process starts, as such defects likely won’t be detected until the structure is complete.
Accordingly, governments need to issue standardized benchmarks and building codes for 3D printers and introduce stricter quality tests for materials before printing starts. Xomerty said that would be difficult, as “it takes considerable time and political will to update building codes.”
This article first appeared in July’s print edition of Business Monthly.
