3D printing, is a newly adopted technique in the construction sector with the aim to improve the economics and alleviate environmental impacts. This study assesses the eco-efficiency of 3D printing compared to conventional construction methods in large-scale structural fabrication. A single-storey 3D-printed house was selected in the United Arab Emirates to conduct the comparative assessment against traditional concrete construction. The life cycle assessment (LCA) framework is utilized to quantify the environmental loads of raw materials extraction and manufacturing, as well as energy consumption during construction and operation phases. The economics of the selected structural systems were investigated through life cycle costing analysis (LCCA), that included mainly the construction costs and energy savings. An eco-efficiency analysis was employed to aggregate the results of the LCA and LCCA into a single framework to aid in decision making by selecting the optimum and most eco-efficient alternative. The findings revealed that houses built using additive manufacturing and 3D printed materials were more environmentally favourable. The conventional construction method had higher impacts when compared to the 3D printing method with global warming potential of 1154.20 and 608.55 kg CO₂ eq, non-carcinogenic toxicity 675.10 and 11.9 kg 1,4-DCB, and water consumption 233.35 and 183.95 m³, respectively. The 3D printed house was also found to be an economically viable option, with 78% reduction in the overall capital costs when compared to conventional construction methods. The combined environmental and economic results revealed that the overall process of the 3D-printed house had higher eco efficiency compared to concrete-based construction. The main results of the sensitivity analysis revealed that up to 90% of the environmental impacts in 3D printing mortars can be mitigated with decreasing cement ratios.

Three-dimensional printing (3DP) has been rapidly evolving to be one of the leading technology fields in the coming decades. However, as in the early years of new technologies, 3DP suffers from technical limitations and various implications. This study focuses on the applications of 3DP in the construction industry, emphasizing its environmental, financial, and social sustainability aspects. A systematic bibliographic analysis was carried out for the relevant publications which increased by 25-fold from 2014 to 2021. The 3D-printed construction projects in the United Arab Emirates (UAE) are presented to demonstrate the early 3DP technology penetration into its booming construction sector. The UAE case is of particular interest from a sustainability perspective due to the environmental footprint of the ample construction activities in the country, combined with the ambitious strategic plans to achieve sustainable development goals. This critical analysis shows that, despite the limited literature, 3DP could potentially be a sustainable alternative with up to 49% less environmental footprint and 78% more cost-effectiveness compared to conventional construction techniques. As the social sustainability aspect was the least addressed, this study discusses relevant social impact indicators and systematic assessment criteria. It is evident that 3DP is already reshaping the future of the built environment, especially in cases where 3DP is advantageous, such as customized designs, quick project delivery, and sustainability-oriented constructions.