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.

India's cement and concrete industry faces significant challenges. The country produced around 390 million tonnes of cement in 2023, the second highest in the world – which also means that India was responsible for the world's second highest carbon emissions from cement production, around 177 million tonnes.

Now new regulations on carbon emissions are coming. At the same time, the country needs to significantly increase its cement production by 2050.

This dilemma also presents a great opportunity to reduce the country's climate impact through innovation: If emissions from India's cement production were reduced by around 25%, this would be equivalent to Sweden's total carbon dioxide emissions.

"It doesn't take much to make a big difference," says cement expert Katarina Malaga, Professor of Sustainable Construction and Vice President Business Development Sustainable Construction at RISE.

Sweden important in reducing climate impact

In fact, Sweden is playing an important role in reducing the climate impact of cement production in India. At COP 28 in Dubai in 2023, Indian Prime Minister Narendra Modi and Swedish Prime Minister Ulf Kristersson agreed to take action to transform the industry and achieve net-zero emissions by 2050.

As part of the bilateral cooperation, the Swedish Energy Agency is running a project on the transition of the Indian cement and concrete industry, where Swedish companies can apply for support for feasibility studies on various solutions that could be commercialised.

"The Swedish Energy Agency's mission is to create partnerships and increase the pace of transition. At the same time, India is one of the fastest growing countries in the world, so there is also a business agenda to take innovations from Sweden and create companies with Swedish involvement in India," says Katarina Malaga.

RISE plays an expert role in the project, with Katarina Malaga, one of Sweden's leading experts in cement and concrete, playing a key role.

"I am acting as an expert and liaising with both the Indian and Swedish companies to help them assess what is really needed in the market and the scientific issues: Could this work?," she says.

Expertise needed as a buffer

The Swedish companies supported are working on energy efficiency and statistical processing, among other things. The next step is for Ms Malaga to take the companies to India to explore the market.

"They are not cement companies, so I am needed as a facilitator to filter certain questions and answer things like how the composition of cement is affected by their solutions," she says.

The aim, of course, is for one or more of the companies to eventually set up in India and help reduce the climate impact of the cement industry. Katarina Malaga sees great opportunities, but expects that it will take time and that it will not be easy. There are big differences in both regulations and culture, which means that Indian partners will be needed.

She says the project is challenging and different from other work she has done for RISE.

"We are faced with completely new questions, it is a challenge, but a very interesting challenge for us researchers, and it is also interdisciplinary," says Katarina Malaga.

The project may also help to establish Sweden as an innovation-oriented knowledge country in India and lead to further collaborations.

"We have already established a partnership with the Indian equivalent of RISE, which can help address these specific issues. Through research, I believe they will be able to change a lot," says Katarina Malaga.

"We work with poor surfaces on steel and concrete and have a number of different techniques to counteract olle in the gate. It can be composite, carbide or ceramic, depending on the nature of the problem," says Mikael Ringsåker, CEO of SST Slitskyddsteknik, and continues:

"The material for which we have now received type approval is used, for example, to repair concrete in swimming pools. "It can be 20-40 millimetres of bad concrete that we remove until we come to fresh concrete. Then we spray on this cement-based coating and smooth it down to a nice finish."

Type approval opens the market

With the wear protection in place, the basin in the treatment plant is protected from erosion and bacterial growth. It is important, of course, that the coating has no negative impact on the drinking water and its quality. In the first project where SST applied the method, the client carried out the evaluation and necessary tests to obtain a hygiene approval.

As the method proved to be both effective and hygienically safe, SST decided to go through the type approval process in order to help more water companies secure their drinking water infrastructure.

"When I presented this pilot project to customers at various trade fairs, many were interested. They all said, 'Get in touch when you have type approval'," says Mikael Ringsåker.

SST had worked with RISE on a project concerning concrete in waterworks and had a good experience with the research institute. When it came to finding a third party that could provide type approval for materials and products in contact with drinking water, RISE was the obvious choice.

Prepared for future legislation

The task was given to certification engineer Jenny Johansson, who reviewed the documentation provided by SST and checked that the supplier's formulation did not contain anything incompatible with contact with drinking water. Colleagues from RISE carried out an inspection visit to the factory where the coating is manufactured to ensure that production meets the certification requirements. After six months, type approval was granted - proof that SST complies with the Planning and Building Act and the building regulations of the National Board of Housing, Building and Planning.

"This is important for the client. Partly because they now have proof that the coating is safe in contact with drinking water, and partly because there will be a new EU directive on materials in contact with drinking water in the near future. The directive will apply from 1 January 2027, but if you have a type approval before then, you can use it until the end of December 2032 while you work towards meeting the EU requirements as well," explains Jenny Johansson.

The type approval process went smoothly, says a satisfied Mikael Ringsåker.

"You could say that we, SST and our supplier of the specific product, paid for qualified people to go through the documentation and carry out this process, and I am very happy that we did. Now we can go to our customers with clear proof that our solution can be used to advantage in the modernisation of the Swedish drinking water network," he says.