Material Science and 3D Printing Redefine Construction
In 2022, laboratories, universities, and startups accelerated the transformation of construction through advances in both material science and fabrication methods. Researchers at Virginia Tech achieved a milestone by building the first permanent structure in the United States using modular hardwood cross-laminated timber (HCLT). The 75-foot-long, 30-foot-high observation tower combined off-site prefabrication with a newly certified timber product, marking a significant step toward low-carbon structural systems.
At ETH Zurich, students demonstrated the aesthetic and structural potential of reclaimed materials with a geodesic dome built from salvaged OSB panels, beams, steel girders, and piping. The project underscored the value of digital material passports for cataloging and reusing components in future builds. In Cairo, engineering students developed luminescent concrete that stores solar energy during the day and emits light at night, aiming to offset concrete’s environmental drawbacks by reducing roadway lighting demands.
Washington State University researchers enhanced cement performance by incorporating nanoparticles derived from shrimp shells. This bio-additive increased concrete strength by 40% and compression load capacity by 12%, while addressing seafood waste and reducing emissions from cement production. Late in the year, the ‘Nave’ terracotta cooling system drew on Palestinian traditions, offering wall tiles, partitions, and freestanding forms that cool water and air using locally sourced clay.
Startups also pursued climate-conscious alternatives. ByFusion introduced recycled plastic blocks with interlocking features similar to LEGO, matching standard concrete block dimensions but producing 41% fewer greenhouse gas emissions during manufacture. MIT scientists unveiled a polymer-based material as light as plastic yet as strong as steel, with potential applications in structural components. The University of Virginia hosted the Biomaterial Building Exposition, showcasing fungal structures and salvaged lumber as viable architectural materials.
Prometheus Materials, backed by SOM, Autodesk, and Microsoft, advanced algae-based masonry as a zero-carbon alternative to Portland cement. “To prevent catastrophic climate change, we cannot simply replace fossil fuels with renewable forms of energy — we must also decarbonize the way we create building materials,” stated the company’s founder. At UNC Charlotte, Professor Kyoung Hee Kim secured $1 million to develop biochromic windows incorporating algae, which adjust tint and color based on sunlight and can be harvested for uses ranging from biofuels to fertilizers. In October, researchers experimented with mushroom mycelium to repurpose asphalt roofing shingles into reusable construction products.
3D printing continued to reshape construction workflows. ETH Zurich’s robotic arm produced foam elements for efficient concrete formwork, enabling reuse and recycling of the foam shapes. MIT developed a lattice material with embedded air channels that detect structural movement via pressure changes. Montana regulators approved 3D printed wall systems as alternatives to conventional concrete, following safety demonstrations by a local contractor and the University of Connecticut. UVA researchers explored soil-and-seed 3D printing to integrate vegetation directly into architectural structures.
Stanford engineers created a high-speed, multi-resin 3D printing process, five to ten times faster than existing high-resolution systems, and began developing software to broaden designer access. ICON received a $57.2 million NASA contract to adapt its 3D printing methods for lunar and Martian construction under the Small Business Innovation Research program.
Real-world applications proliferated. ICON and Lake|Flato unveiled “House Zero” in Austin, a 2,000-square-foot home with curved printed walls that enhance circulation and sustainability. Students at IAAC built TOVA, a zero-waste housing prototype from raw earth sourced within 164 feet of the site. Cornell professors Leslie Lok and Sasa Zivkovic embarked on the first multistory 3D printed structure in the U.S., combining printed concrete with timber framing.
ETH Zurich’s ‘eggshell pavilion’ showcased algorithm-driven geometry and robotic fabrication for efficient concrete shaping. In Georgetown, Texas, BIG and ICON began constructing Wolf Ranch, a community of 100 printed homes with varied exterior styles and printed interior textures. The University of Maine completed BioHome3D, the world’s first fully bio-based printed home, assembled in half a day and equipped with sensors to monitor thermal, environmental, and structural performance through winter.
