Army builds first 3D-printed barracks

The U.S. Army completed a pilot program in which new 3D-printed barracks were constructed at Fort Bliss, Texas.

The barracks house 72 soldiers each and, at 5,700-sf, are the largest 3D-printed structures in the Western Hemisphere, according to a Newsweek report. If the Army uses this technology more widely, it could reduce construction costs, speed up deployment, and make infrastructure more durable in both domestic and combat settings.

Using mold-resistant materials, the barracks were engineered to withstand environmental hazards, including severe weather and seismic activity. The Department of Defense collaborated with Austin-based ICON, which used a large gantry-style 3D printer to make the buildings out of Lavacrete material. The machine uses a proprietary concrete-based material called Lavacrete, which can be tailored to local environmental conditions, including humidity and temperature, ensuring optimal performance and aesthetic appeal, according to the Army. 

This initiative was spearheaded by the Army’s Defense Innovation Unit, which is testing new construction methods for durable and energy-efficient housing construction at lower costs.

According to the Army, the facilities on West Bliss are the first 3D-printed structures to comply with the Defense Department’s updated Unified Facilities Criteria, a mandate updated annually that provides construction guidance DOD-wide and now reflects standards for additive manufacturing, or 3D-printed, facilities.

The newly opened facilities will initially house troops deploying to Fort Bliss in support of the installation’s Mobilization Force Generation Installation mission. Fort Bliss processes and trains approximately 70,000 service members annually, with support from Army Reserve and National Guard units that deploy to Fort Bliss for annual rotations.