Qatar has started what is being described as the world’s largest 3D printed construction project. The 3D Printed Schools Project is a collaboration between UCC Holding and the Public Works Authority (Ashghal). It includes 14 public schools, with two of them built using 3D printing technology. Each printed school will have a built area of 20,000 m², adding up to 40,000 m² in total. This footprint is reportedly 40 times larger than the biggest 3D printed building completed so far.

Large-Scale 3D Printing Technology

To carry out this project, UCC Holding worked with COBOD, a Danish company known for construction-scale 3D printing. COBOD supplied two custom BODXL printers. Each printer is 50 metres long, 30 metres wide, and 15 metres high. These machines build walls layer by layer by extruding a cement-based mixture guided by digital models. After printing, workers install roofs, doors, windows, and complete the interior.

The project applies additive manufacturing at a scale rarely seen in public architecture.

Architecture and Construction Process

The schools’ designs take inspiration from Qatar’s desert landscapes. Their curved forms mimic the shape of sand dunes. These shapes are difficult and costly to build using conventional methods, but 3D printing allows greater design freedom.

Before full construction began, UCC’s team conducted over 100 trial prints using a smaller BOD2 printer. These trials helped develop concrete mixtures suited to local conditions. They also tested the machines’ performance and designed a custom print nozzle to improve precision.

To avoid high daytime temperatures, construction takes place at night. This also helps reduce dust, noise, and improves concrete curing.

Environmental Benefits

The project aims to reduce its environmental impact. 3D printing uses less concrete than traditional construction and produces less waste. On-site printing also limits the need for transport, which can reduce emissions and improve logistics. These factors support faster construction and lower the overall carbon footprint.

Timeline and Relevance

The full 14-school complex is scheduled for completion by the end of 2025. The two printed schools serve as a pilot for expanding digital fabrication in the region.

This development is relevant to architects, interior designers, and product designers interested in digital manufacturing, sustainable materials, and large-scale public infrastructure.

Source & Photos: UCC Holding / COBOD / New Atlas
Photo: COBOD