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Retail giant Walmart has initiated one of the largest 3D printed commercial real estate projects in the United States at its Supercenter in Athens, Tennessee.
As mentioned in a Wall Street Journal (WSJ) news report, this 8,000-square-foot expansion, built to accommodate items ordered online for pickup or delivery, represents Walmart’s effort to explore the potential of 3D printing technology in construction.
Alquist 3D, the company responsible for the 3D printing component of the project, worked closely with FMGI, a long-standing contractor for Walmart. Together, they combined traditional construction methods with 3D printing technology to bring the expansion to life.
Evaluating construction 3D printing’s effectiveness
With more than 200 similar projects in the pipeline, Walmart is evaluating whether 3D printing can deliver faster and more cost-effective results compared to traditional construction methods. Patrick Callahan, CEO of Alquist 3D, explained that the Athens project serves as a key test case, highlighting both the potential benefits and challenges of using 3D printing in commercial real estate construction.
The Athens expansion faced delays, mainly due to Tennessee’s extreme summer heat and humidity. Construction crews encountered problems with materials overheating and equipment like clogged hoses, resulting in a longer completion timeline than anticipated. Although the overall cost of using 3D printing was roughly equivalent to traditional construction methods, Walmart remains focused on improving cost-effectiveness in future projects.
Despite the setbacks, Callahan expressed optimism. He noted that the project progressed more efficiently as it continued, and Walmart has already hired Alquist 3D for another project. Alquist 3D and FMGI anticipate that the insights gained from the Athens project will lead to improvements in future timelines and processes.
Mike Neill, Walmart’s Vice President for U.S. Construction, added that Walmart regularly explores new technologies to enhance its operations. After evaluating the possibilities of 3D concrete printing, Walmart identified it as a technology worth considering for its construction projects.
Walmart’s continued exploration of 3D printing reflects its intent to refine the technology for greater efficiency in future construction projects.
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A broader look at Alquist 3D’s construction novel projects
Away from Walmart, Alquist 3D has been involved in other construction 3D printing projects highlighting the advantages of this technology. One notable example includes Alquist 3D’s plans to build 200 3D printed homes in Virginia, marking the largest construction 3D printing project in the U.S.
After its success in Richmond and Williamsburg, the firm focused on Pulaski and Roanoke, where demand for housing had risen due to workforce growth. For this project, Alquist 3D used Black Buffalo 3D’s NEXCON system to accelerate construction, capable of building 1,000 sq. ft. homes in under 20 hours, says the company.
Alongside COBOD, PERI Group, Habitat for Humanity, and Printed Farms Florida, Alquist 3D used 3D printing to construct low-cost homes in rural parts of the United States in 2021. Constructed in Arizona and Virginia, these homes were designed to be faster and cheaper to construct than traditional houses, while still providing durability.
Additionally, Alquist3D’s 1,200 sq. ft. 3D printed home in Williamsburg and its earlier project in Virginia, demonstrate the potential for addressing housing shortages in rural areas through affordable and accessible construction methods.
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Featured image shows a bird-eye view of Walmart’s construction 3D printing project. Photo via WSJ.
