Additive Manufacturing (AM) enables the production of three-dimensional objects through the layer-by-layer addition of materials such as plastics, metals, or concrete, offering significant advantages over conventional subtractive methods. Within AM, 3D Concrete Printing (3DCP) stands out for its ability to produce complex, high-precision structures with greater design freedom and cost efficiency. In construction, AM initially supported scale modeling, but its true potential lies in enabling customized, multifunctional designs while addressing sustainability and productivity challenges. By eliminating formwork, optimizing material usage, reducing waste, and lowering CO₂ emissions from cement, 3DCP significantly improves environmental performance. Automation further reduces physical labor, human error, and construction-site accidents.

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A major milestone was achieved in 2017 with the world’s first 3D-printed concrete bridge in Gemert, followed by projects in Nijmegen and Eindhoven. These successes led to the founding of Zavhy B.V., focused on scaling 3DCP for infrastructure. Subsequent innovations, including fiber- and cable-reinforced technologies (FRED and RED), demonstrated up to 75% cement reduction, 75–85% lower environmental impact, reduced shrinkage, and doubled tensile strength, confirming technical and economic feasibility. However, widespread adoption is hindered by the absence of building codes, reliance on destructive testing, and challenges in first-time-right production.

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This project aims to bring Zavhy’s 3DCP technology to TRL8 and increase social acceptance by developing predictive models (Qugate), a digital twin and control system (AGMAH), and further validating Zavhy’s patented technology. Together, these developments enable digital quality assurance, eliminating destructive testing and improving sustainability and cost efficiency. The integrated system is expected to reduce downtime by 40%, increase production efficiency by 30%, and significantly improve first-time-right manufacturing.

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The project will deliver strong technical, economic, and social impacts, including accelerated market adoption, substantial sales growth for all partners, job creation, major CO₂ reductions, and contributions to climate and energy transition goals. Overall, it represents a crucial step toward safe, scalable, and sustainable implementation of 3DCP in construction and infrastructure.