As the world’s population continues to grow, the demand for new homes and infrastructure is rising rapidly.
At the same time, concerns about climate change and carbon emissions are pushing scientists to find cleaner, more sustainable building materials.
Now, researchers at Oregon State University have developed a fast-curing, environmentally friendly alternative to traditional concrete that could one day be used to 3D print houses and other structures.
3D printing, also known as additive manufacturing, is already starting to change the construction industry.
Instead of building with bricks or pouring concrete into molds, large printers can extrude material layer by layer to form walls, roofs, and other parts of a building.
This method has the potential to build structures more quickly, with less waste and lower labor costs. However, it still relies heavily on concrete, which presents major environmental challenges.
The main problem is cement, the key ingredient that binds concrete together. Making cement requires extremely high temperatures—more than 1,400 degrees Celsius—which are usually produced by burning fossil fuels.
This process releases large amounts of carbon dioxide into the atmosphere. In fact, cement production is responsible for around 8% of the world’s total carbon emissions. On top of that, concrete can take weeks to fully harden, slowing down construction and requiring additional supports while it cures.
The material developed at Oregon State is very different. Instead of relying on cement, it is made mostly from soil mixed with hemp fibers, sand, and biochar.
Biochar is a carbon-rich material created by heating wood and other plant matter in a low-oxygen environment. These natural ingredients already make the material much more environmentally friendly than traditional concrete.
What makes it especially promising for 3D printing is how quickly it hardens. The researchers used a special acrylamide-based binding agent that triggers a chemical reaction called frontal polymerization.
As the material is pushed out of the 3D printer’s nozzle, it begins to cure almost instantly. This means it can hold its shape right away, even when printed across open gaps, such as above a window or door frame.
Immediately after printing, the material is strong enough to support further layers placed on top of it.
Within just three days, it reaches and even exceeds the strength required for the structural concrete used in typical homes. Traditional concrete can take up to 28 days to reach similar strength levels.
This major difference could dramatically speed up the construction process, which is especially important after natural disasters when shelter is urgently needed.
Although the early results are very promising, the team acknowledges that more work still needs to be done. At the moment, the material costs more than regular concrete, so the researchers are looking for ways to reduce its price. It must also undergo standard safety and performance tests before it can be approved for widespread use in real construction projects.
Even so, this discovery represents an exciting step toward greener, faster, and more sustainable building methods. In the future, 3D-printed homes made from eco-friendly materials like this one could help address housing shortages while also reducing humanity’s impact on the planet.
