As cities become more crowded and construction companies struggle to find enough workers, the building industry is searching for faster and more efficient ways to complete projects.
One promising solution is 3D concrete printing, a technology that uses machines to “print” building components layer by layer.
Now, researchers at the National University of Singapore (NUS) have shown that this technology could do much more than previously thought — including producing strong structural parts for buildings while reducing labor, costs, and environmental impact.
In the past, 3D concrete printing was mostly used for decorative or non-structural elements because of concerns about strength and reliability.
The NUS research team, led by Dr. Du Hongjian and Associate Professor Pang Sze Dai, focused on overcoming those limitations.
They developed new methods showing that printed concrete components can meet the strict performance requirements needed for structural use, meaning they could support real buildings rather than just serve as add-ons.
The researchers combined advanced 3D printing techniques with traditional construction methods to create practical solutions for real construction sites.
They designed special concrete mixtures that can be smoothly printed while still becoming strong after hardening.
They also developed a workflow that fits into existing building processes, making it easier for companies to adopt the technology without completely changing how they work.
Tests in laboratories and large-scale trials showed that the printed components could carry heavy loads while using much less material than conventional concrete structures.
Automation also reduced the need for manual labor.
Industry evaluations found that manpower requirements could drop by more than 40 percent, while efficiency for complex components could improve by over 60 percent.
Without the need to build temporary molds for each part — a major cost in traditional construction — projects could move faster and allow more flexible designs.
The technology has already moved beyond the lab. In August 2025, the team collaborated with construction company Woh Hup to carry out Singapore’s first on-site 3D printing of structural building elements, verified by the country’s Building and Construction Authority.
That project cut labor hours in half, proving that the approach can work under real conditions. A second on-site trial began in January 2026 to further test the method in everyday construction environments.
Beyond speed and efficiency, the researchers are also addressing environmental concerns. Concrete production is a major source of carbon emissions, largely because of the cement used in the mixture.
To make the process more sustainable, the team developed a new printable concrete that replaces 60 percent of traditional cement with recycled glass powder. Despite using waste material, the new mix still achieved high strength suitable for structural components.
Laboratory results showed that this greener concrete could be printed into full-scale elements without collapsing and reached compressive strengths strong enough for building use.
Compared with conventional printable concrete, the new material reduced energy use by 44 percent and carbon emissions by 52 percent. It also showed improved durability, suggesting structures made with it could last longer and require less maintenance.
The researchers believe that 3D concrete printing could help transform construction in high-density cities where land is limited and efficiency is essential. By reducing manpower needs, speeding up building times, and lowering environmental impact, the technology supports broader goals for sustainable urban development.
With continued collaboration between universities, industry partners, and government agencies, 3D concrete printing may soon move from experimental projects to everyday construction sites. If widely adopted, it could change not only how buildings are made but also how cities grow in the future.
