To support the expansion, materials producer Sika signed an exclusive arrangement to supply concrete and related compounds for every Alquist 3D project and licensee. Alquist expects the partnership to reduce freight costs, create a predictable supply chain and fast-track development of lower-carbon concrete mixes tailored to large-format printers.
Patrick Callahan, chief executive of Alquist, said the firm designs its own printers, develops proprietary code to run them and trains operators in-house. He argued that moving into higher volume commercial work will lower unit costs by attracting larger orders from suppliers and enabling continuous operation of the printers rather than single bespoke jobs.
The Athens pilot exposed early hurdles. Because Alquist joined after architectural plans were complete, the company had to adapt its process to designs and permits originally intended for traditional construction. These adjustments lengthened the schedule, though precise timing was not disclosed. Lessons learned fed directly into the next project—a roughly 5,000-square-foot pickup center in Huntsville, Alabama—that Alquist printed in seven days.
While 3D printing reduces the number of on-site laborers, the method depends on technicians versed in robotics, software and sustainable materials. Alquist has partnered with vocational schools to integrate these skills into construction curricula, positioning the jobs as cleaner and safer alternatives to conventional trade roles. The company’s strategy targets a workforce that has thinned in recent years; according to the U.S. Bureau of Labor Statistics, job openings in construction have remained well above pre-pandemic levels since mid-2021.
The competitive landscape is also evolving. Texas-based Icon Build, widely regarded as the largest U.S. residential 3D printing firm, has completed a hotel and is negotiating with potential partners on data centers and other industrial facilities. Icon’s upcoming “Titan” printer is being engineered for projects larger than its existing residential systems, and the company plans to deliver at least one Titan unit per month next year. Icon executives have highlighted the same cost and schedule advantages pursued by Alquist but caution that skilled labor availability remains a significant constraint.
Imagem: Internet
Commercial real estate construction has historically adopted new technologies more slowly than the residential sector, partly because of the scale of the buildings and the capital at risk. The Walmart-Alquist program represents a pivotal test of whether additive manufacturing can meet the durability, code compliance and speed demands of high-throughput retail properties. Current equipment is limited to low-rise structures, but both Alquist and Icon say future iterations could handle larger footprints and more complex designs.
As production ramps up, Alquist is aligning with a national equipment rental chain and a full-service general contractor to supply printers and manage site work. The goal is to create a replicable template that can be shipped, installed and operated with local crews after a short training period. The company expects these efficiencies to tighten construction timelines further and reduce cost volatility tied to traditional materials.
For Walmart, the initiative fits into broader efforts to optimize last-mile logistics by expanding dedicated pickup and delivery areas attached to existing stores. By printing the shell of each building on site, the retailer aims to shorten project schedules and limit disruption to day-to-day store operations.
If the next wave of buildings proceeds as planned, the projects could move 3D printing closer to mainstream acceptance in commercial real estate, offering a scalable alternative amid persistent labor shortages, budget pressures and sustainability mandates.
Crédito da imagem: Alquist
