Innovative Construction Method Revolutionizes Housing
In Georgetown, Texas, ICON’s Vulcan printer is transforming the construction landscape. This massive machine, over 45 feet wide and weighing 4.75 tons, operates like a desktop 3D printer but on a much larger scale, building residential homes layer by layer.
This summer, ICON is finishing the last few of 100 3D-printed houses in Wolf Ranch, a community located about 30 miles from Austin. The project, which began in November 2022, is touted as the world’s largest 3D-printed community. ICON claims this method is faster, less expensive, requires fewer workers, and significantly reduces construction material waste compared to traditional methods.
Efficiency and technological advancements
ICON’s senior project manager, Conner Jenkins, highlights the efficiency brought by the new technology: “Where there were maybe five different crews coming in to build a wall system, we now have one crew and one robot.”
The process involves mixing concrete powder, water, sand, and other additives, which are then pumped into the printer. The nozzle extrudes the mixture, layer by layer, along a pre-programmed path, creating corduroy-effect walls. These concrete walls are designed to be resistant to water, mold, termites, and extreme weather.
Homeowner experience
Lawrence Nourzad, a 32-year-old business development director, and his girlfriend Angela Hontas, a 29-year-old creative strategist, recently purchased a home in Wolf Ranch. Nourzad described their new home as a “fortress,” confident in its resilience against tornadoes. The couple also noted the excellent insulation, which keeps their home cool even during the Texas summer.
However, the thick walls posed a challenge for wireless internet connectivity. To address this, most Wolf Ranch homeowners use mesh internet routers, which broadcast a signal from multiple units placed throughout the home.
Pricing
The 3D-printed homes, called the “Genesis Collection,” range in price from around $450,000 to nearly $600,000. Developers report that over a quarter of the 100 homes have already been sold.
ICON, which first 3D-printed a home in Austin in 2018, has ambitious plans beyond Earth. NASA has contracted ICON to develop a construction system capable of building landing pads, shelters, and other structures on the lunar surface as part of the Artemis Moon exploration program.
This groundbreaking project in Texas not only showcases the potential of 3D printing to revolutionize housing but also sets the stage for future advancements in space construction.