3D Printed Polymer Composites Reshape Concrete Construction

Oak Ridge National Laboratory (ORNL), in partnership with Kairos Power and Barnard Construction, is applying large-scale 3D printing to build concrete forms. These forms are being used in the construction of the Hermes demonstration reactor in Tennessee, US.

Faster Formwork with Polymer Composites

The project team prints the forms using carbon-fibre-reinforced ABS, a strong and lightweight composite material. Each form measures about three metres wide and tall. The forms are stackable and built to shape detailed concrete structures.

Unlike traditional formwork made from steel or timber, this method allows for faster production and more complex designs. For example, forms that usually take weeks to produce can now be made and installed within days. This speeds up construction while reducing material waste.

Broader Use in Design and Architecture

While the current application supports a nuclear energy project, the technique has wider potential. Designers and architects can apply this technology to create custom concrete elements for buildings, infrastructure, or products. It enables greater design flexibility, faster delivery, and more efficient use of materials.

Supporting Innovation and Sustainability

The project is part of the SM2ART Moonshot Project, which focuses on improving construction through advanced technologies. One major goal is to switch from plastic-based materials to biocomposites made from timber industry waste. This could lower costs by up to 75% and improve sustainability.

In addition, the project includes smart technologies, such as digital twins and real-time monitoring, which help improve quality and reduce risk. These tools also support better planning and faster decision-making.

A New Direction for Construction

By combining additive manufacturing, material innovation, and digital tools, this project shows how the construction industry can evolve. The method opens new opportunities for professionals who aim to build efficiently and reduce environmental impact.

Source: Oak Ridge National Laboratory
Photo: Kairos Power