Build Big, Think Bigger

This evolving frontier is challenging our old notions of how to build, design, and produce. Architects, engineers, designers, and researchers alike are finding that it opens up unprecedented possibilities in form, function, and sustainability.

So, does that mean it’s a tool for everyone?

“Well, yes and no. But I’d say many sectors, from small enterprises to large multi-national companies, could really benefit from exploring its potential,” says Marie-Louise Bergholt, Director of the Application Center for Additive Manufacturing (AM Center) at RISE. “And, honestly, if you already have a robotic arm around, transforming it into a 3D printer isn’t all that difficult.”

What Robotic 3D Printing Can Do

In essence, robotic 3D printing employs programmable robotic arms to lay down precise layers of materials – whether concrete, metal, polymers, composites or even organic substances – in specific configurations. Instead of the “remove and refine” methods we’ve relied on, additive manufacturing technologies builds layer upon layer, using only the exact amount of material needed. The result? Shapes, designs, and structures that were once impossible or prohibitively expensive to create.

This freedom is more than just a technical advantage – it unlocks new ways of thinking. The technology makes it possible to produce large-scale structures, several metres in size, such as boats, buildings, bridges, or furniture, in entirely new ways. It also promotes greater circularity. 

“We discard vast amounts of furniture today. Pieces are shipped across the world, used for only a few years, and then thrown away. With 3D printing, furniture can be produced on demand, reducing energy consumption in warehousing and cutting the need for discounting unsold products – a practice that can drive overconsumption. The technology also allows manufacturers to send a digital file to a local supplier, replacing long-distance transport with local production,” says Johanna Vesterberg, founder of Normada Open Source Furniture. 

The first product Normada created using robotic 3D printing was a recyclable sofa, named The Nest (Image 2 in the slideshow below). The sofa was made from a biocomposite of oil and cellulose derived from Nordic pine trees and was developed in collaboration with AM Center at RISE. The ambition was for the sofa to closely resemble the handcrafted wooden model.

“We knew it would stand out. We wanted to push the boundaries of the industry and prove that it’s possible to 3D print furniture with a Scandinavian design aesthetic – without the futuristic look that 3D-printed furniture often has,” says Johanna. 

New and Future Possibilities

Since Johanna Vesterberg designed The Nest, the technology has matured significantly, and Normada, alongside a growing number of companies from various sectors, has continued to explore the possibilities of robotic printing at RISE.

Simultaneously, RISE has integrated advanced software, refined both methods and materials, and combined printing with milling in one continuous process. Most recently, RISE opened a new test and demonstration facility dedicated to concrete 3D printing.

“Since we at RISE already had extensive experience with robotic printing for polymers and composites, as well as access to advanced toolpathing and automated quality assurance, the concrete printing testbed was set up quickly and efficiently. The fact that we can now print larger structures with a wider range of materials opens up entirely new possibilities for functional and sustainable building solutions,” says Ojas Arun Chaudhari, project manager for materials design at RISE.

“However, unlike polymer-based printing, concrete printing presents greater challenges in areas such as rheology, hydration kinetics, and time-dependent behaviour, which require real-time process control. As concrete cannot be remelted like thermoplastics, curing time affects both layer bonding and buildability.”

One of the companies that jumped at the chance to try concrete 3D printing was the Swedish producer of concrete and natural stone products, Benders.

“We see great potential in 3D printing. Given the complexity of products like pipes and manholes, we are exploring how this technology could help address these challenges. Benders also manufactures a range of other products, such as roof tiles, paving stones, slabs, and prefabricated elements. We will evaluate the current 3D printing project to determine if it can be applied to any of these areas,” says Kjell Ryberg, Technical Manager at Benders, adding:

“While 3D printing is an important part of our development, it’s equally crucial to consider the type of concrete used, especially in relation to the products' future exposure.”

Woodrow Wiest, research engineer at the Application Center for Additive Manufacturing, is in alignment with Kjell Ryberg. Material properties are a key driver in the effectiveness of large format additive manufacturing. 

“Robotic additive is indeed impressive especially considering its relatively early stage of development. Our research takes part in ushering this evolution forward, focusing on the convergence of robotics, process planning, material properties, sustainability, while also keeping a keen eye on market competitiveness. As technology continues to evolve, we can expect to see robots printing in more and more industries in the near future,” he says.

A New Way of Thinking

While robotic 3D printing may still feel like an emerging field, it’s one that’s brimming with untapped potential. For those working in construction, design, architecture, manufacturing, or art, this is a technology that invites exploration. By challenging traditional manufacturing processes, it becomes possible to create lighter, stronger, and more complex shapes with less material waste and a lower environmental impact.

The expertise at RISE covers a broad spectrum, from material development and sustainable manufacturing to built environments and bioeconomy. By collaborating with companies and organisations across various sectors, we have the opportunity to further develop robotic 3D printing and identify new areas of application.

RISE welcomes businesses from all industries to explore how robotic 3D printing can shape the future of manufacturing. Get in touch with Marie-Louise Bergholt, Director of AM Center, or Ojas Arun Chaudhari (for inquiries regarding concrete printing) to learn more.