ETH Zurich: Introducing a new robotic method in 3D-printing field as a more sustainable alternative

ETH Zurich researchers introduced a revolutionary 3D-printing technique that is known as Impact Printing. This robotic method uses natural materials like sand, silt, clay, and gravel. This innovative approach aims to reduce carbon emissions and offers a cost-effective alternative to traditional 3D printing methods. The most significant feature of this method is that it allows structures to be made from locally sourced, recyclable earth materials, reducing both environmental impact and expenses.

An SNSF Bridge Fellow at ETH Zurich, Lauren Vasey stated that the research team developed a robotic tool and process to transform excavated materials from construction sites into building products. Contrary to conventional 3D printing, that relies mostly on cement-reinforced materials, “Impact Printing” is developed to use only natural components, minimizing the use of additives. Specifically, during the process, finer materials like clay serve as binders, while coarse materials such as sand and gravel provide strength, allowing for seamless movement through the robotic system without clogging.

To start the printing process, they provide the robotic tool with a digital blueprint that will guide it to project the material at high speeds (up to 32 feet per second). Then once printing starts the robotic tool builds the structure layer by layer without the need for cement. This method yields durable structures, including walls up to 6.5 feet tall capable of supporting additional load. Despite its compressive strength (around 2 MPa) being lower than concrete, it is suitable for constructing two-story structures.

In all, ETH Zurich plans to commercialize “Impact Printing” through a prefabrication facility, while they are anticipating market readiness within three years. It should be noted that, the University of Virginia also introduced a 3D-printable concrete alternative, using a graphene-enhanced clay mix, that is promising 31% less emissions while another project by TU Berlin and Brunel University integrates recycled glass into 3D printing concrete, enhancing strength and thermal insulation.