Project Outcomes
3D printable concrete is a major step toward sustainable construction. Its layer-by-layer method allows precise material placement, reduces waste by 70–90%, and eliminates the need for wood molds and metal forms, lowering both cost and carbon footprint compared to traditional Ordinary Portland Cement (OPC) concrete. However, current feedstocks rely on carbon-intensive Type IL cement with chemical additives. Developing decarbonized 3D concrete feedstocks can maximize both the environmental and functional benefits of 3D printing.
ProZERO™, developed by Prometheus Materials, is the first carbon-negative supplemental blend designed as a 1:1 replacement for OPC cement. This project aimed to identify, evaluate, and optimize ProZERO™ feedstock formulations for 3D printing by screening various cement additives and refining their material properties to ensure printability, structural integrity, and compatibility with 3D printing processes.
The project involved an intensive literature review on 3D printing concrete and mixtures that enable it, as well as several iterations of identifying and testing potential formulations.
The project’s key deliverables included a 3D Concrete Printing Feedstock Research Summary, a literature review database, and nine feedstock formulas recommended for further testing. This work lays the groundwork for future research on additive behavior in mixtures containing ProZERO™.
Continued development of ProZERO™ feedstock formulations for 3D printing could enable rapid, cost-effective construction of housing and shelters while simultaneously reducing global warming potential.
Key technology/tools used: JMP Statistical Discovery
