For electrical construction, 3D printers will change the way installations take place. With new standards and a willingness from some general contractors to proceed with more projects, the industry may be at the start of a new trend that will affect construction in residential and other sectors in the coming years.

Currently, 3D-printed buildings are still rare in the United States and, in some cases, experimental. The process consists of “printing” the three-dimensional structure of a building or home using a CAD design, and the material is deposited by the robotic printer according to the specifications. Robotic printers lay successive layers of the materials over a mold, building up from floor to ceiling.

The material is typically concrete or cement, but it can also be wood, foam or polymers. Proponents say the technology has the potential to revolutionize the construction industry by making the building process faster, cheaper and safer.

Until recently, one of the challenges for adoption internationally was the lack of a certification process for approval of a 3D-printed building’s structural elements, said Stephan Mansour, additive construction specialist and consultant for Wohlers Associates, Washington, D.C. Mansour is also on international standards organization ASTM’s F42-07-07 construction subcommittee and is co-convenor of ISO/TC 261/JG 80 for the development of additive construction standards.

Mansour has led an effort to create innovative technologies for the building industry, including 3D printing. His team conducted a 2018 pilot project in Saudi Arabia for the National Housing and Industry Development and Logistics Program west of Riyadh’s airport.

However, at the time, Mansour said, “one of the biggest issues that came up from the general contractor’s perspective was that we could not verify the structure that we built. There were no codes and standards on how to actually certify this building.” And without certification, “they cannot issue a warranty, they cannot issue insurance, and they cannot guarantee that the building can stand for the length of time that it’s required to.”

Mansour moved to Canada in 2020 and started the ASTM committee to address standards for construction 3D printing. Under his guidance, the ISO/ASTM 52939 standard for additive manufacturing for construction was published in December 2023.

That could lead to more projects in the future. Mansour helps institutions and companies adopt 3D printing. With standards in place, the goal is to mitigate the risk for those advancing the technology.

Most projects are starting off with residential structures, then expanding to commercial buildings, bridges and roads. (For more on 3D printing’s residential roots, check out “Added Dimensions” in the October 2021 issue of ELECTRICAL CONTRACTOR.) Bridges have already been printed in Europe for pedestrian and bicycle use.

“We’re studying bridge performance,” Mansour said. After the next few years, as such structures prove themselves, “That’s where the technology and the applications will increase.”

Benefits of 3D construction

The foremost benefit to 3D printing is safety, he said. “If we have a robotic arm or robotic system that can actually handle the hazardous environment and all the lifting, then we don’t have to put people or workers at risk.”

Mansour added, however, that it may also offer work for individuals who were previously excluded from construction work due to disabilities or the inability to lift heavy items.

It also offers a flexibility in material use that can lead to more sustainable buildings. 3D printing enables use of construction waste materials, such as recycled wood powder mixed with plastic that creates a wood aesthetic that’s actually stronger than pure lumber.

Change is coming. In 2020, only six companies provided 3D-printing products or services for construction in North America, while in 2024, there are more than 400 companies globally,
by some estimations.

With standards and certification in place, Mansour added, that number is likely to grow.

The changing roles for electrical contractors

The changing landscape of work will mean more computer design and remote control, and less physical labor. Those providing CAD design and printer control, even remotely, will be in demand. By digitizing the process, contractors serve to benefit from artificial intelligence if they are trained in programming and digital design.

In a 3D-printed building, contractors would no longer need to cut into the walls to run cable, for instance. Instead, the conduits are already printed into place. When the structure is completed, electricians come on-site to finish the wiring and sockets and take the electrical system live.

Typically, electrical engineers and contractors would have a role in mapping out the electric design, and being on hand if the electric service is printed into the building. The same is true for HVAC and plumbing subcontractors.

Rollouts starting with research and testing

One company providing 3D printers and services for projects around the world is AC3D, San Francisco.

“Currently our majority of activities are in the United Arab Emirates, while we already have a signed contract to supply a printer to a U.S. general contractor,” said Boris Kozlov, the company’s founder. That project will be made public in the coming months.

AC3D has several business models. It creates the printers for use off- and on-site. One example is a relatively small laboratory printer that Kozlov refers to as an entry-level 3D printer for universities and scientific or research facilities to start experimenting.

AC3D can also bring a larger printer on-site or nearby. Some early customers include companies that want to print concrete parts for decorations or city beautification, or for more industrial parts and purposes, such as prefabricated insulated panels.

The pinnacle of the company’s portfolio, Kozlov said, is a large-scale, on-site printer that can be installed on a new project’s foundation and can print the whole building.

To help launch the technology for a building industry still learning about its features and capacity, AC3D provides full printing service at some sites. The company has its own in-house capacity subcontractor to help provide the actual manufacturing.

“We are promoting our equipment by executing projects,” Kozlov said. The company can adjust to a builder’s architecture and structural preferences, “so whatever customers need from us, we provide them.”

Printing electrical infrastructure

In some cases, the wiring is installed during the printing process. Typically, most electric wiring is run directly through walls or floors. In a house, for instance, the electrical wiring can be run inside the slab underground, and Kozlov pointed to the importance of electrical contractors in that wiring process.

“When you cut the cavities in the foundation for electricity and plumbing, it requires a lot of precision. If you miss a place for a wire [for example], sometimes you create big problems for yourself,” he said.

With 3D printing, design can also be more creative. 

“We’re not limited to the same fixed shapes used in conventional approaches.” From design to completed construction, “3D printing streamlines the process; it becomes digital from the beginning to the end,” Kozlov said. “So I think the electrical contractors will just be an integral part of that.”

Another 3D printing approach is offered by Mighty Buildings, Oakland, Calif., which recently began working with the California Energy Commission (CEC) as part of an initiative to develop and deploy sustainable housing solutions that meet the state’s energy efficiency and environmental standards.

   

Mighty Buildings was founded in 2017 and has its roots in advanced manufacturing and material science research, said Alexey Dubov, the company’s co-founder and chief innovation officer.

The company’s goal is to create sustainable, high-quality homes more efficiently and at a lower cost than traditional construction methods, he said. As part of the CEC project, the company will build homes that integrate with California’s energy grid to optimize power use. This partnership will include one of the first larger-scale deployments for Mighty Buildings, demonstrating how 3D-printed homes can meet strict energy regulations and serve the state’s ambitious sustainability goals.

The structures will come with built-in solar photovoltaic panels paired with a small battery in tandem with envelope design and equipment intended to be highly efficient, including a mini-split heat pump system.

The “cool rooms” that are part of the project will reduce peak loads by shifting to low-power operation during times of acute grid stress and by moving the peak load from a concentrated single period in the evening to multiple scattered periods throughout the day. The goal will be to provide greater resilience through events such as power outages, as well as extreme temperature events, while generating more consistent billing cycles and a 10-year lower total cost of ownership, Dubov said.

Modular approach

Mighty Buildings’ manufacturing process primarily uses advanced composite materials, which include a proprietary stone-like material that offers the strength and durability of concrete, but is much lighter, Dubov said. 

“This material is ideal for 3D printing as it can be quickly cured using UV light, allowing us to create complex structures with minimal waste,” he said.

Unlike wood, which can be susceptible to pests, rot and other environmental factors, the Mighty Buildings materials are designed to be long-lasting, sustainable and more efficient—both in terms of energy use and construction time.

Mighty Buildings takes a different approach to 3D printing than some of its competitors. The company typically deploys a modular printing approach, producing components off-site in a controlled environment and then assembling the fabricated pieces on-site. This method offers several advantages, such as greater quality control, faster production times and the ability to easily transport and assemble the components, Dubov said.

When it comes to electric and other services, they are part of the printing process. 

“In our 3D-printed homes, electrical systems, plumbing and other utilities are integrated during the construction process,” he said.

During the design phase, these services are planned to ensure they are embedded seamlessly into the walls and floors.

“This approach reduces the need for additional work after the main structure is built and allows for precise placement of wiring, outlets and other components, which is particularly beneficial for installers and integrators who require consistency and accuracy in their work,” Dubov said.

3D-printed homes are likely to have a significant effect on the electrical trade in the future, Dubov said. As these homes become more common, electricians and integrators will need to adapt to working with prefabricated systems and components that are integrated into the home during the printing process. Integration of prefabricated systems will require involvement from electricians and engineers. 

“As we print and construct the components, it’s essential to ensure that all electrical systems, including wiring, outlets and panels, are accurately placed according to the design specifications,” he said.

For contractors, it means a shift in roles, he added. “This presents an opportunity for the electrical trade to specialize in new types of installations, including smart home systems and advanced energy management technologies.“

Electricians’ roles may shift from traditional wiring to more technical and specialized tasks, potentially increasing demand for advanced skills in automation and smart systems. Keep an eye out.

stock.adobe.com / guteksk7 / Destina // AC3D