Construction 3D printing firm Alquist 3D has completed a second project with retail giant Walmart, delivering a 5,000 sq. ft. pickup expansion at the Owens Cross Roads Supercenter in Alabama.
The build took one week to finish, with a five-person team from Alquist using two printers to construct 16 ft high walls in 75 hours over seven working days. According to the construction firm, it was the fastest timeline it has recorded for a project of this scale and came in at a lower cost than conventional construction methods.
Supporting efforts on the ground, FMGI managed site coordination to ensure smooth integration between printed elements and other construction tasks. Meanwhile, Sika USA provided the concrete mix, which was specifically formulated to support the fast-paced build while maintaining structural performance.
“We’re proving that 3DCP is cheaper and greener than standard CMU construction,” said Darin Ross, President and CEO, FMGI. “This build cost 15% less and produced 55% less waste than the first 3DCP build late last year in Athens, Tenn.”
Material efficiency and cost control through automation
The goal was to address two of the most persistent challenges in commercial development: speed and cost. Alquist pointed to a mix of automation, reduced labor needs, and tighter control over materials as the key factors behind the project’s pace and efficiency.
Although the crew had budgeted for 130 bags of mix, the job was completed using just 94, a 28% drop that helped keep material waste under 5%. Precise deposition and better planning contributed to the outcome, allowing the team to avoid overuse while still meeting structural requirements.
Automation also allowed the team to carry out tasks typically handled by a larger workforce. With no need for scaffolding or bracing, site safety improved and timelines tightened. The project continued uninterrupted despite weather conditions that would usually delay masonry work, which helped keep things on track.
This build follows a previous collaboration between the two companies last year at Walmart’s Supercenter in Athens, Tennessee. That earlier project involved an 8,000 sq. ft. expansion and marked one of the largest commercial 3D printing efforts in the country at the time.
Execution proved more difficult, with delays caused by extreme summer heat and equipment issues such as clogged hoses. While the final cost in Athens was roughly on par with traditional methods, the experience laid the groundwork for process improvements. Both Alquist and FMGI say lessons learned there directly informed planning for the Alabama build.
Adding to that, LB Johnson, Vice President of Construction at Walmart said, “Our approach to innovation is designed to optimize processes and simplify field operations – leading to reductions in project costs and timelines. This will enable speed to market for our customers and help accelerate evolution in the construction industry.”
Alongside its construction work, Alquist is investing in training programs to support the growing role of 3D printing in the construction industry. The company has partnered with Aims Community College in Greeley, Colorado, to develop a curriculum focused on large-scale additive construction. The program combines technical instruction with hands-on experience, and is part of Alquist’s broader effort to prepare a workforce for emerging roles in automated construction.
Fastest construction projects
Speed in construction via 3D printing is making waves in countries globally. One notable example includes construction at Hatsushima Station in Wakayama Prefecture, where the West Japan Railway Company (JR West), working with JR West Innovations and Serendix, completed a 3D printed station building in just 6 hours.
A compact reinforced concrete structure, decorated with cultural motifs, was assembled overnight to avoid train service interruptions. This pilot project explored whether 3D printing could offer a faster, more cost-effective approach to upgrading rural stations, while also addressing labor shortages and evaluating maintenance efficiency for future railway infrastructure projects.
Recently, Contec Australia completed Western Australia’s first multi-story 3D printed house in Tapping, showcasing speed benefits of construction 3D printing. Using a robot from Dutch company CyBe Construction, Contec’s team printed 15 walls of a 155 sq. m. structure in just 10.5 hours of active printing, with second-floor walls following within 18 hours.
A small crew handled the process, which ran efficiently in open air despite 42°C temperatures. This project demonstrated how 3D printing can accelerate construction timelines while maintaining performance in demanding environments and with minimal labor.
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Featured image shows Walmart’s 5,000 sq. ft. pickup expansion at the Owens Cross Roads Supercenter in Alabama. Photo via Alquist 3D.
