The 175th Civil Engineer Squadron pioneers expeditionary 3D concrete printing technology to rapidly construct fortified infrastructure for military operations.
United States US Air Force has received and successfully fielded a new 3D concrete printing system for rapidly constructing bunkers and other fortifications in austere environments, representing a leap forward in military construction technology.
The 175th Civil Engineer Squadron at Martin State Air National Guard Base in Maryland developed Expeditionary 3D Concrete Printer, which can quickly build infrastructure to sustain military operations while employing few personnel.
“The idea came from carefully considering the role of Air Force Civil Engineers in future conflicts,” said Maj. Brian Vickers, Deputy Base Civil Engineer and project manager for the printer. “Our ability to rapidly construct and repair austere airfields and infrastructure on a large scale will likely be strained in future conflicts.”
Unlike traditional construction methods which demand extensive manpower, time, materials and specialized skills, the new printing system requires only three Airmen to operate and uses concrete, one of the world’s most widely available building materials.
The system provides enhanced protection for military personnel. “By building with concrete, occupants of these buildings are far more protected from blasts, fragmentation, and small-arms fire,” Vickers explained. The printer’s ability to create curved walls offers superior blast resistance while concrete’s natural thermal properties improve both survivability and energy efficiency.
Early testing highlighted the need for greater durability and mobility. Working with industry partner X-Hab 3D, the team reinforced components, automated processes, and simplified controls to make the printer field-ready and combat-capable.
Following training at Penn State University in April 2024, the 175th Civil Engineer Squadron became the first operational Air Force unit with a 3D concrete printer. Within a month, they completed their first independent on-base print.
The technology has already demonstrated impressive resilience. During one test, Tech. Sgt. Joshua Frost attempted to destroy a fresh print with a sledgehammer 18 hours after completion but was unable to break it. “The concrete was so hard; far stronger than typical concrete, a tremendous nod to the potential uses of this technology,” said Vickers.
Future plans include printing a full-sized structure to house the equipment itself, potentially creating “a model for a concrete replacement of the SSS Tent that has been a DoD standard for several decades,” according to Vickers.
The Air Force believes this innovation will trickle from specialized engineering units into more general engineering forces, greatly expanding construction and repair capabilities throughout the service.
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Along with commercial and other academic partners, we can reimagine military construction with the Expeditionary 3D Concrete Printer, providing the Air Force a faster, safer way to construct key infrastructure — giving our Airmen the ability to satisfy the demands of complex missions by building whatever they require, where and when they need it.”
