How 3D Printing and AI Are Transforming Construction and Enhancing Safety

How 3D Printing and AI Are Transforming Construction

Tools have always been central to construction, whether it’s an architect’s drafting program or a craftworker’s hammer. Today, advances in technology offer new ways to tackle construction challenges, improve efficiency, and enhance safety on job sites.

Paola Sanguinetti, director of The Design School at Arizona State University’s Herberger Institute for Design and the Arts, points out that automation is becoming more common in construction. “The construction industry is fragmented due to the many companies and trades involved. It’s complex, but manufacturing and technology can help streamline the process,” she says.

3D Printing in Construction

3D printing, a technology familiar in consumer markets, is gaining traction for building structures. It works by breaking down a digital model into layers, which a robotic arm then prints using materials like concrete. This layer-by-layer approach creates building components efficiently.

Concrete is the most common material used, though it presents challenges. Research from ETH Zurich explores printing with a dry material bed, fusing particles with heat instead of using wet concrete. This method is cleaner and more precise.

In 2021, Habitat for Humanity built over 70% of a 1,738-square-foot home using a 3D printer. Sanguinetti observed the process firsthand and noted how climate impacts printing. “In Germany’s summer, the concrete dried too quickly, which affects curing and binding,” she explains. Environmental conditions are critical for success with wet materials.

Sustainability is a focus in ongoing research. Geopolymer concrete, which replaces Portland cement with fly ash, reduces the carbon footprint. Adding phase change materials improves insulation by absorbing and releasing heat, allowing thinner walls and lowering energy use for heating and cooling—especially beneficial in hot climates like Arizona. However, these additions affect how well the mixture prints, so finding the right balance is key.

In commercial projects, some companies use 3D printing to prefabricate parts off-site, similar to tilt-up construction. Detailed components like facades still require traditional methods due to precision needs. Overall, 3D printing cuts labor, speeds up fabrication, and changes how buildings come together.

Enhancing Safety with AI

AI technology is also improving safety on construction sites and in logistics. Sunstate Equipment recently equipped its vehicle fleet with Netradyne’s Driver•i D-450 system, which uses a four-camera setup for a 270-degree view around the vehicle. AI analyzes the surroundings and alerts drivers in real time to potential hazards.

Mike Safsten, director of safety and risk at Sunstate, shares that the system has prevented incidents by warning drivers about pedestrians or obstacles they couldn’t see. The system issues audible alerts for unsafe driving behaviors like speeding. If ignored, it records video sent to both drivers and managers for coaching.

Rather than monitoring to catch errors, the system encourages safe habits and reduces accident risks. Video is reviewed only when warnings are ignored or collisions occur. Safsten emphasizes the system acts as a “driving partner,” helping drivers stay focused amid distractions and safely deliver loads.

Successful adoption depends on building trust between management and drivers. “Installing the technology alone isn’t enough,” Safsten says. “You need a culture that accepts monitoring and supports open communication to avoid disrupting operations.”

As 3D printing and AI continue to advance, construction professionals can expect more efficient workflows and safer job sites. For those interested in expanding their skills in AI and automation, exploring relevant training can provide a competitive edge. Check out Complete AI Training’s latest AI courses to stay up to date with these technologies.